Article excerpt from the September/October 2018 issue of Metal Casting Design & Purchasing.
The common practice allows designers the freedom to achieve many different parts via an evolving method of production.
The green sand casting process is the most widely-used process for casting ferrous and nonferrous metals. The process has evolved from a manually intensive operation to a highly mechanized and fully automated process.
In terms of weight, complexity and alloy composition, a wide range of castings can be produced via green sand casting. In terms of shape, the process can be used to cast parts as simple as ingots and as complex as engine blocks. It is commonly used for ferrous alloys; however, it can be used for almost any alloy, including those of aluminum, copper, magnesium and nickel.
One of the major advantages of green sand casting is its low cost, especially when mass-producing castings on highly automated molding and coremaking equipment. Another major advantage of green sand is its versatility with respect to production. The process can be economically applied to small and large production runs. In addition, the production rate can be increased by making multiple mold cavities in a single mold.