CASTING SOURCE

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DUCTILE IRON SAND CASTINGS

CAST - MACHINED - FINISHED

Ductile iron sand casting is an easy and economical process to create basic parts 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. Ductile iron sand castings are often used to make prototypes, due to the speed and relative low cost of production when compared to other manufacturing techniques.

The ductile iron 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 ductile iron 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 improve the net shape. Simple molds are open at the top and melted ductile iron is poured into the mold. When the ductile iron cools the sand is removed and the sand casting is ready for secondary operations, such as machining and finishing.