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Green Sand Metalcasting Foundry News

Metal Casting Systems - Choosing Between Nobake and Green Sand

Posted by Hill and Griffith Company on Jul 2, 2019 5:35:28 PM

Navigate the differences in capabilities and cost factors between nobake and green sand metal casting molding processes to ease your sourcing decision.

Opting for a sand casting process over permanent mold, diecasting, or investment casting is step one in sourcing a casting. But sand casting encompasses several methods, each of which carries its own advantages and disadvantages. The two most common processes used are green sand and nobake molding, and sourcing between the two is not always cut and dry.

Forty-two percent of North American metalcasters employ the green sand molding process.  Its popularity stems from its affordability, ability to be used for most metals and flexibility for low to high volume production.

Green sand molding does not hold the tightest tolerances or achieve the finest surface finish of all the casting processes; however, in general, it meets most of the qualifications desired to produce a high quality casting with a good finish.

Nobake sand casting, which is utilized by 40% of North American metalcasters, also is known for its versatility. Virtually all metals can be cast via nobake molding, a wide range of sizes can be produced, and the rigid mold walls provide good dimensional tolerances and control.

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Tags: Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Release Agents, Foundry Supplies, Green Sand System, Green Sand Metalcasting, Modern Casting Magazine, Metal Casting Design & Purchasing

Review of American Foundry Society's "Core Processes"

Posted by Hill and Griffith Company on Feb 5, 2019 3:45:49 PM

An editorial review of AFS's "Core Processes" Chapter from the "Casting Buyer's Guide"

Hill and Griffith specializes in compounds and coatings for Green Sand Foundry Process patterns and cores. This post highlights a few parts of the "Casting Buyer's Guide" chapter two on "Core Processes." With a better understanding of cores, you will understand our diverse product selection.
 
"One of the reasons castings are so widely used in all types of applications is due to the great design flexibility to form the internal shape of a casting which is inherent in a variety of processes available to produce a core.
 
The core, which is usually a pre-formed sand aggregate (metal for die casting), is inserted into the mold to shape the interior of a casting or that part of a casting which cannot be shaped by the pattern. The core is located and held in the mold by core pockets, formed by the pattern. In areas where the core may be thin in cross-section or require additional support to maintain metal wall thickness, chaplets are used.
 

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Tags: Metal Casting, Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Release Agents, Metal Casting Supplies, Foundry Supplies, Green Sand Metal Casting, Green Sand System, Green Sand Metalcasting, AFS Casting Buyers Guide

Review of AFS Glossary Foundry Terms: "Permeability" to "Vent"

Posted by Hill and Griffith Company on Jan 24, 2019 1:22:47 PM

A partial review of The American Foundrymen's Society's Glossary of Foundry Terms from the "Casting Buyer's Guide"

Permeability - The property of a mold material to allow passage of gases.
 
Physical properties - Properties of matter such as density, electrical and thermal conductivity, expansion, and specific heat. This term should not be used interchangeably with '' mechanical properties.''
 
Pig iron - Blocks of iron to a known metal chemical analysis used for melting, with suitable additions of scrap, etc., for the production of ferrous castings.
 
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Tags: Metal Casting, Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Release Agents, Metal Casting Supplies, Foundry Supplies, Green Sand Metal Casting, Green Sand System, Green Sand Metalcasting, Glossary Foundry Terms

Review of Reliance Foundry's, "How to make green sand for metal casting foundry" article

Posted by Hill and Griffith Company on Jan 15, 2019 5:23:16 PM

This is a great basic description of the "Green Sand" foundry method.

"Molding sand is at the heart of the sand casting process. It must hold a shape well and capture the fine details of a casting, yet be permeable enough to allow gases to escape. Under the strain of having the molding pattern removed from it, or while it is filled, it cannot crumble or sink on itself. When it is turned upside down it must not lose its form: the parts of a mold have to stay true while clamped together.

In most cases, “green” sand is enough to evidence these properties. Green sand is not called that because of its color—these materials can be a wide range of colors depending on composition and use. Instead, it gets its name because it is damp, like green wood.
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Tags: Metal Casting, Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Release Agents, Metal Casting Supplies, Foundry Supplies, Green Sand Metal Casting, Green Sand System, Green Sand Metalcasting

Review of AFS Glossary Foundry Terms: "Foundry returns" to "Patternmaker's shrinkage"

Posted by Hill and Griffith Company on Jan 8, 2019 5:25:13 PM

A review of The American Foundrymen's Society's Glossary of Foundry Terms from the "Casting Buyer's Guide"

Foundry returns - Metal in the form of gates, sprues, runners, risers, and scrapped castings of known composition returned to the furnace for remelting.
 
Gas porosity - A condition existing in a casting caused by the trap­ping of gas in the molten metal, or by mold gases evolved during the pouring of the casting.
 
Gate (ingate) - The portion of the runner where the molten metal enters the mold cavity. Other gates: bottom -any gating system by which metal enters the mold cavity at the bottom.
 
Green sand - Moist clay bonded molding sand.
 
Heat - A single furnace charge of metal to be used for pouring directly into mold cavities; a heat may be all or part of a master heat.
 
Heat treatment - A combination of heating and cooling operations timed and applied to a metal or alloy in the solid state in a manner which will produce desired properties.
 
Hotbox process - A furan resin-based process which uses heated metal coreboxes to produce cores.
 
Hot tear - Irregularly shaped fracture in a casting resulting from stresses set up by steep thermal gradients within the casting during solidification and too much rigidity of the core or mold material.
 
Inclusions - Particles of slag, refractory materials, sand or deoxida­tion products trapped in the casting during solidifica­tion.
 
Investment casting process - A pattern casting process in which a wax or thermop­lastic pattern is used. The pattern is invested (sur­rounded) by a refractory slurry. After the mold is dry, the pattern is melted or burned out of the mold cavity, and molten metal is poured into the resulting cavity.
 
 
Ladle - A container for molten metal used to transfer metal from the furnace to the mold.
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Tags: Metal Casting, Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Release Agents, Metal Casting Supplies, Foundry Supplies, Green Sand Metal Casting, Green Sand System, Green Sand Metalcasting, Glossary Foundry Terms

Green Sand Foundry Technology Video

Posted by Hill and Griffith Company on Jan 2, 2019 9:40:05 AM

Thanks to Belloi & Romaqnoli for this great animation of the green sand foundry process.

Green Sand Preparation, Tight Flask Molding, Rotary Sand and Casting Cooling Shakeout Technology 

"A modern foundry sand preparation system must meet two fundamental requirements, it must produce quality sand and it must continue to deliver this quality over time. Belloi & Romagnoli systems guarantee the supply of quality sand with the right compatibility and green strength with a temperature level below 45 degrees, which is permeable and constant over time. Now, let's see how.

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Tags: Metal Casting, Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Release Agents, Metal Casting Supplies, Foundry Supplies, Green Sand Metal Casting, Green Sand System, Green Sand Metalcasting

Review of AFS Glossary Foundry Terms: AQL to Flask

Posted by Hill and Griffith Company on Dec 27, 2018 6:02:16 PM

A review of The American Foundrymen's Society's Glossary of Foundry Terms from the "Casting Buyer's Guide"

AQL - Acceptable Quality Level. A quality level established on a prearranged system of inspection using samples selected at random.

As-cast condition - Casting without subsequent heat treatment.

Backing sand - The bulk of the sand in the flask. The sand compacted on top of the facing sand which covers the pattern.

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Tags: Metal Casting, Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Release Agents, Metal Casting Supplies, Foundry Supplies, Green Sand Metal Casting, Green Sand System, Green Sand Metalcasting, Glossary Foundry Terms

Happy Holidays!

Posted by Hill and Griffith Company on Dec 18, 2018 9:29:29 AM

Season's Greetings from our family to yours.  

Hill and Griffith's Management & Sales Team 

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Tags: Metal Casting, Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Release Agents, Metal Casting Supplies, Foundry Supplies, Green Sand Metal Casting, Green Sand System, Green Sand Metalcasting, Happy Holidays

"Foundry Management & Technology, 2019 Metalcasting Outlook"

Posted by Hill and Griffith Company on Dec 11, 2018 2:04:22 PM

North American foundry and diecasting managers and decision makers give the final word on industry conditions today — and the first word on their expectations for metalcasting growth and development in the coming year.

 

Foundry Management & Technology, "2019 Metalcasting Outlook."

Metalcasting is not an ordinary industrial market: it is sensitive to all types of economic variables (raw materials, energy, labor) as well as financial conditions (interest rates, tariffs.)

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Tags: Metal Casting, Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Release Agents, Metal Casting Supplies, Foundry Supplies, Green Sand Metal Casting, Green Sand System, Green Sand Metalcasting, Foundry Management & Technology magazine, Metalcasting Outlook

Feeling Out Green Sand Conditioning

Posted by Hill and Griffith Company on Dec 5, 2018 3:35:21 PM

• This article looks at the characteristics metalcasters should be looking for in their sand systems.

• Explained within is the role additives play in creating ideal molding sand characteristics.

For many metalcasters, there is no substitute for the smooth and silky feel of perfect green sand conditioning. While there have been many improvements in sand conditioning practices to achieve this feel, tests designed to determine ideal sand characteristics remain subjective, causing foundries to rely somewhat on guesswork.

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Tags: Metal Casting, Green Sand Casting Products, Green Sand Foundry Supply, Foundry Supply, Green Sand Release Agents, Metal Casting Supplies, Foundry Supplies, Green Sand Metal Casting, Green Sand System, Green Sand Metalcasting, Foundry Core Coating

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