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Green Sand Metalcasting Foundry News

Aluminum Foundry Green Sand Metal Casting Video

Posted by Hill and Griffith Company on Nov 18, 2020 2:16:18 PM

 (This week's post is from Alcast Technologies's video of the aluminum green sand foundry metalcasting process.)

"Alcast Technologies uses only the best automated molding technologies available to produce the industry's highest quality green sand molds while maintaining unparalleled productivity standards. Two state of the art Roberts Sinto FBO series Flaskless Molding Machines are used to produce molds within a 16" x 20" frame and a 20" x 24" frame. These investments have significantly improved mold design flexibility and give Alcast a distinct advantage over more rigid and antiquated automated technologies."

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Tags: Green Sand Casting Products, Green Sand Foundry Supply, Core Pastes, Foundry Supply, Green Sand Release Agents, Foundry Supplies, Pattern Release Agent

Green Sand Publications from the American Foundry Society

Posted by Hill and Griffith Company on Nov 10, 2020 9:12:14 PM

The 2019 AFS Publications Catalog just came out and there are many titles that can help you with Green Sand and Permanent Mold metalcasting applications.

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Tags: AFS, Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Release Agents, Foundry Supplies, American Foundry Society e-Learning

Green Sand Casting Process

Posted by Hill and Griffith Company on Nov 3, 2020 5:01:03 PM

Excerpt from the Metal Casting Institute website.

Green sand casting is generally considered the easiest casting system because it is possible to use an existing part as a pattern for a one-off project. However, it is also used for some high volume projects also. The major benefit of this process is that the sand is easily recycled with low smell and a low ecological impact. When used to form parts out of aluminum alloys, the sand mixture has an impact on the final quality due to the potential for hydrogen gas pick up in the metal from the moisture in the sand. Therefore, with aluminum, green sand is generally used to form simple shapes and parts that aren't susceptible to leakage.

The process has four primary factors considered important:

  1. Sand Quality
  2. Pattern precision and alignment between cope and drag
  3. Gating and riser design
  4. Metal Control

 

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Tags: Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Coatings, Green Sand Release Agents, Green Sand Metalcasting, Core Binders, Green Sand Additive Products

Following the Trends to Better Designs, Better Castings

Posted by Hill and Griffith Company on Oct 27, 2020 5:08:18 PM

Excerpt from the September 2020 Foundry Management & Technology Article by Robert Brooks.

CAD meets casting simulation, and then 3D printing, as a specialty manufacturer effectively converts another complex assembly to a more efficient, lightweight casting.

One or two technology cycles ago, metal casters were enthusiastically adopting simulation programs to identify the causes of quality defects during casting production. That wave of development, still in progress, was prompted by the emergence of CAD programs that optimized casting design. One trend line in the current metal casting technology cycle is adaptation of CAD files to guide additive manufacturing programs, as in 3D-printing of bonded sand into optimally designed molds and cores.

Now, all these trend lines are converging with still another initiative in metal casting — redesigning castings (or fabrications, or other assemblies) as lighter, more functionally effective cast structural elements of vehicles, machines, etc. In the example of one manufacturer, coordinating these trends also made it possible to expedite the design of a customized machine to maximize the potential of its market niche.

 

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Tags: Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Coatings, Green Sand Release Agents, FOUNDRY Management & Technology, Green Sand Metalcasting, Core Binders, Green Sand Additive Products

Changes to New Sand Additions at Cadillac Casting

Posted by Hill and Griffith Company on Oct 20, 2020 7:29:57 PM

Excerpt from the October 2020 Modern Casting Article by Travis Hepfner.

An AFS Green Sand Division revealed foundries are handling new sand additions differently from what has historically been standard. Here, one foundry shows why and how it eliminated new sand additions altogether.

A recent survey by the AFS Green Sand Division asking foundries about their new sand addition practices revealed what was once considered a common practice was not so definitive for every plant. While 300 lbs. of new sand per 1 ton of iron poured has been an industry baseline, discussions with many sand foundries showed that for some, the practice of adding new sand had been eschewed for using their core sand as “new” molding sand.

In the survey of 47 sand foundries, 10 were not adding new sand, other than the core sand input. One of those foundries was AFS Corporate Member Cadillac Casting. While presenting at the virtual 2020 Sand Casting and Additive Manufacturing Conference last month, Travis Hepfner, quality engineer at Cadillac Casting, shared the foundry’s path to eliminating new sand additions.
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Tags: Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Coatings, Green Sand Release Agents, Green Sand Metalcasting, Core Binders, Green Sand Additive Products, Modern Casting Magazine

Solidification Structure in Sand Casting

Posted by Hill and Griffith Company on Oct 13, 2020 3:44:58 PM

Excerpt from the Complete Casting Handbook (Second Edition) 2015 by John Campbell.

External chills

Placing a block of metal on the pattern in a sand mold and subsequently packing the sand around it to make the rest of the mold is a widely used method of applying localized cooling to that part of the casting. A similar procedure can be adopted in gravity and low-pressure die-casting by removing the die coat locally to enhance the local rate of cooling. In addition, in dies of all types, this effect can be enhanced by the insertion of metallic inserts into the die to provide local cooling, especially if the die insert is highly conductive (such as made from copper alloy) and/or artificially cooled, for instance by air, oil or water.

Such chills placed as part of the mold, and that act against the outside surface of the casting, are strictly known as external chills to distinguish them from internal chills cast in and become integral with the casting.

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Tags: Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Coatings, Green Sand Release Agents, Green Sand Metalcasting, Core Binders, Green Sand Additive Products

Aluminum Sand Casting

Posted by Hill and Griffith Company on Oct 6, 2020 4:43:00 PM

 

EnginSoft shows essential advantages of sand casting as one of the fastest and most cost-effective casting methods adopted in the production of metal prototypes.

Article excerpt from the April 2018 article on SpotLightMetal.com website edited by Isabell Page.

Sand Casting is an excellent solution for low to medium runs of parts that do not require precise shape repeatability, as well as being the only solution for very large objects which cannot be produced with other mass production casting techniques.

Sand is an excellent low cost cast material because it is refractory and chemically inert. Sand casting is also ideal for the production of very complex components requiring sand cores (cold box or shell sand) for the most intricate details and having internal areas with variations in thickness.

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Tags: Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Coatings, Green Sand Release Agents, Green Sand Metalcasting, Core Binders, Green Sand Additive Products, SpotLightMetal.com

Additive Manufacturing and Metal Casting

Posted by Hill and Griffith Company on Sep 30, 2020 8:41:14 PM

Article excerpt from the June 2019 issue of Modern Machine Shop by Timothy Simpson

According to the American Foundry Society, metal castings can be found in 90% of all durable goods, and you are seldom more than 10 feet away from a casting. I didn't believe it at first, but if nearly every car, truck, train, tractor or construction vehicle has a casting in it, not to mention all the castings found in our infrastructure (buildings, pipelines, etc.), then you understand why that number is so high.

So, how is additive manufacturing (AM), one of the newest manufacturing methods, disrupting metal casting, the oldest manufacturing method? It is pretty simple actually, and it goes along the lines of what we have been discussing recently, namely, hybrid manufacturing approaches in which AM is being used to create the fixtures, jigs, and/or tools (in this case, sand molds and cores) that are then used to manufacture parts by conventional means (in this case, metal casting). In fact, 3D sand printing is probably one of the easiest and least risk ways of integrating AM into production. We know how casting works; all we are doing is finding a faster and cheaper way to make the molds for them, and then we cast and finish components like we have been doing for hundreds of years.

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Tags: Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Coatings, Green Sand Release Agents, Green Sand Metalcasting, Core Binders, Green Sand Additive Products, Modern Machine Shop

Cast System: An Inside Look at Edelbrock's Foundry and Casting Techniques

Posted by Hill and Griffith Company on Sep 22, 2020 3:44:27 PM

Excerpt from On All Cylinders July 15, 2016, automotive blog post by Stephen Kim. 

Running 6.80s at nearly 210 miles-per-hour, today's 275mm drag radial door-slammers incinerate the quarter-mile thanks to obscene levels of airflow and grip. Producing close to six horsepower per cubic-inch requires immense cylinder pressure that can split blocks, blow head gaskets and melt pistons in a jiffy. Fortunately, the aftermarket has methodically eliminated each of these weak links in recent years. While enhanced short-block durability is obviously a good thing, it places an even greater burden on the cylinder heads to keep all that pressure sealed inside the block. To meet the demands of today's boost-hungry race engines, casting technology has evolved tremendously to spawn a new crop of incredibly durable cylinder heads.

While Edelbrock is best known for its extensive line of cylinder heads and intake manifolds, over the last 25 years, the company has quietly established one of the most sophisticated foundry facilities in the country. Initially, the foundry's primary focus was elevating the quality of its street castings, but as racers continued pushing the limits of durability, Edelbrock developed many key technological advancements in an effort to create the strongest race castings in the business. In fact, when engineers realized that they had reached the limits of their first foundry, Edelbrock built a second foundry in 2007 better suited to the low-volume manufacturing requirements of its race cylinder heads.

The combination of old school know-how and modern technology allows Edelbrock to dynamically adapt its casting process as circumstances dictate.

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Tags: Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Coatings, Green Sand Release Agents, Green Sand Metalcasting, Core Binders, Green Sand Additive Products, TheMetalCasting.com

Three Types of Casting Sand

Posted by Hill and Griffith Company on Sep 15, 2020 5:34:16 PM

Excerpt from an article from TheMetalCasting.com 

There is no substitute for good, fine casting sand for metal casting. The experiments with the use of common foundry sand proved to be completely disappointing for packing and retaining its shape when dry. Casting of sand is the simplest and most versatile of all casting methods used to produce castings. There are various types of sand used in casting. These different types of casting sand have their own advantages and disadvantages. The type of metal required to be cast influences which additives and what gradation of sand is used.

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Tags: Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Coatings, Green Sand Release Agents, Green Sand Metalcasting, Core Binders, Green Sand Additive Products, TheMetalCasting.com

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