|View More Examples in the Work Gallery|
Ductile Iron Coated Sand Cast Part
Sand Casting Parts
Large CI Body Sand Casting
Sand Casting Parts
Sand Casting Plant
For simple to complex metal parts, sand casting is one of the best and most versatile casting processes there is. It is an ideal casting solution for small quantities or large runs.
Pouring hot metal into sand molds is an ancient method of manufacturing metal parts and metal items. For proof that sand casting works, just look at its history—the first clay molds that were used to cast decorative items date back to China’s Shang Dynasty circa 1600 BCE. Sand casting has been around for millennia for one simple reason: you can use this process to cast just about anything!
Advantages of Sand Casting
At Deeco Metals, we use the sand casting process to produce a wide range of industrial and architectural metal parts from many different metals. We supply as-cast parts but prefer to supply machined castings, as this helps us find defects during the machining process.
We provide full project consultation to help you:
- Choose the best method of manufacturing your parts
- Suggest the material best-suited to your parts
- Refine your designs to match the manufacturing method chosen
- Find ways to save on costs
Other distinct advantages of Sand Casting
Sand castings impose few restrictions on product shape
The only significant exceptions are the draft angles that are always needed on flat surfaces oriented perpendicular to the parting line. With good patterns and tooling, the proper choice of molding sands and careful foundry practice, surprisingly intricate details can be reproduced in this manufacturing process.
Dimensional control and consistency
Dimensional control and consistency in sand castings ranges from about ±0.030 to ±0.125” (± 0.8 to 3.2 mm) depending on the size and design of the parts being cast. Within this tolerance range, the more generous tolerances apply across the parting line.
Surface finish ranges between approximately 300 and 500 gin (7.7 - 12.9 gm) rms
Sand castings are relatively inexpensive compared to other manufacturing processes
The process is quite simple and most any metals can be used. Parts can be used as is or can be machined.
Sand castings are acceptably precise and above all, highly versatile
This process can be applied to simple shapes as well as castings of considerable complexity, and it can be used with all metals such as cast and ductile irons, copper alloys, steel alloys, stainless alloys, and other complex metals.
Sand castings also lend itself to low volume production or high volumesContact Deeco Metals today to request a quote or to learn more about how Sand Casting can work for your project.
Sand Cast Parts
Because sand molds are very versatile and adaptable to design parameters, just about any shape is achievable. Sand casting can produce a wide range of different parts in weights ranging from less than an ounce to thousands of pounds. Deeco Metals excels at casting parts with simple to complex geometries for industries across the industrial and architectural spectrums. Some examples of the parts we produce are listed below.
Mechanical & Architectural Parts
Through sand casting, we’re able to replicate simple and complex designs for mechanical and architectural parts with accuracy and efficiency. Fully machined castings can be quoted and are preferred, as we reject substandard parts.
Small to Medium Size Parts
- Gearboxes and housings
- All types of valve and strainer parts, bodies & housings
- Pump parts, bodies & housings
- Water fittings
- Flywheels & handwheels
- Architectural products
- Fence post parts
- Marine anchors
- Shipbuilding parts
- and much more
- Equipment housings
- Large parts for road trailers
- Large pipe fittings: elbows, Ts, connectors, etc.
- Wind power fittings & housings
- Off-road equipment parts
- Heavy machine bases
- and much more
Automotive Service Industry Parts
Automotive service industries rely on Deeco Metals for top-shelf sand cast parts. Some examples of auto and truck parts we manufacture via sand casting include:
- Cylinder heads
- Engine blocks
- Engine exhaust manifolds
- Transmission cases
- Brake drums
- Wheel Housings
- Steering parts
- and many other parts
Custom Sand Casting at Deeco Metals
Our foundries can produce custom patterns in wood or aluminum to use in the sand casting process to produce any new or legacy metal parts you require. No matter what industry you’re in, Deeco can supply the metal parts you need! Contact us to request a quote or to schedule a consultation.
What is Sand Casting?
The sand casting process requires a wooden or metal pattern, sand core box, a furnace to melt metal, and finishing equipment to machine cast parts, as needed. Molten metal is poured into the sand cast mold and, after it has cooled, the sand is removed. The metal part is then fettled—metal flash, risers, and spruce are removed—and surface-treated via shot blasting or a similar process. Parts are then finish machined.
Metal can be obtained from specked out ingots or from scrap metals that are melted and alloyed to the specifications required.
- The first step in the process is placing the wood or metal pattern, which replicates your metal part design, into a metal or wooden sand mold box.
- Next, the box is filled with sand, which is compressed firmly around the mold/pattern to form the part cavity. Generally, a resin is added to the sand ahead of molding so it cures solidly around the pattern.
- The mold is carefully removed from the flask or box, leaving behind a cavity in the sand.
- Molds are typically made in two halves: an upper portion (the cope) and a lower portion (the drag). When these two halves are placed together, they form the complete cavity into which molten metal is poured through a spruce or runner (hole in the cavity). The boundary between cope and drag is known as the parting line. A riser (vent hole) that allows gas to escape as molten metal fills the cavity is also needed. This can be part of the pattern or it can be added manually after the two sand mold halves are placed together.
- Metal is melted in an electric induction or gas-fired furnace to the required temperature and is ladled or poured through the spruce to fill the mold cavity that was formed by the pattern. Gasses and air escape through the riser; once this hole is filled with molten metal, it indicates that the mold cavity has been filled completely.
- Once the metal has had time to solidify and cool, the sand is removed.
- The metal runners and risers are still part of the casting part; these are cut off with a cutting wheel or removed by a band saw or metal saw. This process is called fettling.
- The castings are then cleaned by various methods (shot blast, etc.) to remove any residual sand and to blend any imperfections or parting lines.
How Common is Sand Casting?
Sand casting parts currently account for about 75% of U.S. foundry production of copper alloy, gray and ductile iron, stainless steel, and aluminum.