Green Sand Metalcasting Foundry News

Excerpt from the November/December 2020 Casting Source by Jiten Shah.

The green sand casting process is the most widely used high-volume process because it is versatile and cost effective. In the case of an oil pan for a combine used in the agriculture industry produced by AFS Corporate Member Wabash Castings Inc. (Wabash, Indiana), the green sand process proved it versatility after eliminating some issues in the old design, which was cast in the semi-permanent mold process. Thanks to the flexibility in gating placement and design changes in the green sand process, the new casting reduced cost by using a common core for two cavities inside the part.

Critical wall thickness is maintained repeatedly with horizontally-parted green sand molding using a rugged common core for two mold cavities.

• Critical wall section thickness (1) in the oil pan is controlled with a massive common core that is well supported at the core print. The main body core has an overhang, like a cantilever, and if not designed carefully, it could sag or deform, resulting in uneven wall thickness. This could potentially lead to shrinkage porosities and non-uniform mechanical properties due to uneven cooling rates of thinner and thicker sections within the same casting.

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While the use of printed sand molds and cores has become increasingly common, two researchers investigated whether longer, thinner cores could hold up during the metalcasting process.

Article excerpt from the Casting Source November 2015 issue by Tom Mueller and Larry Andre.

One of metalcasting’s major advantages, when compared to other methods of manufacturing, is its ability to produce geometrically complex components. Metalcasting allows designers to put metal only where it’s needed because liquid metal can flow into the open mold cavity. Often, cores are placed into a mold to form an interior part of a casting. These inserts, often made of sand, prevent the molten metal from filling the entire mold, so interior cavities can be included in the casting design.

In recent years, the growth of 3-D printing capabilities has become a topic of interest for every manufacturing industry. In metalcasting, the process offers the potential of producing complex molds and cores with desirable mechanical and physical properties. Printed cores and molds allow for immediate evaluation of design iterations without the additional costs and lead time associated with tooling, which speed the development of cast components for end users.

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Different Types of Sand Molds and Cores Used by Your Supplier Will Impact the Surface Finish of Your Castings.

Excerpt from Casting Source Magazine Jan/Feb 2016 issue

For many casting buyers, a smooth, uniform surface finish is more than a visually appealing bonus. It can be a sign that the casting supplier has produced a high-quality component. Perhaps more importantly for the casting buyer, a proper surface finish can lead to eventual cost savings in the cleaning, finishing and machining of the part.

Castings produced in sand molds can have relatively smooth surfaces, but if need be, the baseline surface finish can be improved through various means, though such gains will come with additional costs. Discussions with casting suppliers can help buyers understand potential solutions and associated costs.

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Tags: Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Release Agents, Foundry Supplies, Casting Source Magazine