CASTING SOURCE

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ALUMINUM SAND CASTINGS

CAST - MACHINED - FINISHED

Aluminum sand casting is an easy and economical process to create basic part shape. Sand casting is the oldest, most common, and simplest of the casting processes. The sand casting process is also the least costly of the casting processes. Normally the sand casting process is used for low temperature alloys, such as aluminum, copper, iron, magnesium, and nickel alloys. However, it can be used for higher temperature metals, such as steel and stainless steel alloys, when other production processes would not be practical. Aluminum sand castings are often used to make prototypes, due to the speed and relative low cost of production when compared to other manufactuing techniques.

The aluminum sand casting process is very simple. A pattern is made in the shape of the desired part. The pattern can be made in wood, plastic, or metal. Simple aluminum sand castings can be made in a single piece, called a solid pattern. More complex designs are made in two parts, called split patterns. The patterns are then packed into sand, mixed with a binder, which helps harden the sand into a semi-permanent shape. Once the sand mold is cured, the pattern is removed, leaving a hollow space in the sand in the shape of the desired part. Cores can be inserted into the mold to create holes and to improve the net shape. Simple molds are open at the top and melted aluminum is poured into the mold. When the aluminum cools the sand is removed and the sand casting is ready for secondary operations, such as machining and finishing.