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sand casting - an overview | sciencedirect topics

Sand casting can be used for the majority of metals. Even highly reactive magnesium is sand cast provided care is taken and the correct materials used by adding what are called inhibitors into the sand.

Sand castings inevitably have a slow cooling rate because of the large insulating mass of sand surrounding the liquid metal as it cools. Grain sizes and dendrite arm spacings tend to be larger than in equivalent section sizes in die-castings. Cooling rates in sand castings range from 106 to 1 C s1, and the expected dendrite arm spacing may be from 50 to 5 mm (66).

Sand casting involves the pouring of molten metal into a cavity-shaped sand mould where it solidifies (Fig.6.8). The mould is made of sand particles held together with an inorganic binding agent. After the metal has cooled to room temperature, the sand mould is broken open to remove the casting. The main advantage of sand casting is the low cost of the mould, which is a large expense with permanent mould casting methods. The process is suitable for low-volume production of castings with intricate shapes, although it does not permit close tolerances and the mechanical properties of the casting are relatively low owing to the coarse grain structure as a result of slow cooling rate.

Sand casting is the process of choice for the aerospace industry for the economical production of small lot sizes. The industry uses sand casting for producing magnesium alloy and certain types of aluminium alloy components with complex shapes. Figure6.9 shows the housing of an aircraft engine made using sand cast magnesium alloy. The housing is a thin wall component containing small diameter cooling holes, which demonstrates the capability of sand casting to produce complex shapes.

Sand casting is one of the oldest casting processes, dating back at least 2000 years. The sand casting moulding method was first recorded by Vannoccio Biringuccio in his book Pirotechnia [1] published around 1540. The technology of sand casting was adapted to aluminium as soon as the metal was available. Companies, such as cast-iron cook wear producer Wagner Ware, converted some of their sand cast capacity to aluminium beginning in 1894. Fig. 5.1 shows an aluminium teapot that was a conversion from an earlier iron design.

Sand casting is a very versatile process and can produce castings of extreme complexity in a wide range of aluminium alloys. Interest in light weighting and improvements in the technology of sand casting has driven the average weight and size of aluminium sand castings upward, with many parts weighing over 50kg and with some parts as large as 100m3. Any aluminium alloy can be cast in sand, including alloys that may exhibit hot shortness in metal mould processes.

There are several categories of sand casting, usually defined by the type of binder used to hold the sand together. There are different sands or artificial aggregates in wide use, each of which can be used in multiple sand casting processes. The most common sand is silica, which is an oxide of the element silicon. Silica sands are the most abundant sand in nature and have satisfactory moulding characteristics. Other sands that are commonly used include olivine, zircon, and chromite. Zircon and chromite sands have low thermal expansion and high thermal conductivity. That high conductivity can be used to improve the soundness and mechanical properties of castings. Synthetic aggregates, including alumina, bauxite, and mullite are used in some special applications. These materials are hard, wear resistant, and spherical, making them an ideal moulding material. Because the cost is higher than natural sands, recycling efficiency needs to be high to make them economically viable. The principal properties required of the moulding media are green strength and flowability, defined as the ability of material to be compacted to a uniform density. Green strength is required so that the pattern can be withdrawn from the mould without distortion or collapse. The balance between strength and flowability is determined based on the compaction method used in the moulding process.

Sand casting is the most commonly used expendable mold process. In this process, sand is bound together (as detailed in Table 7.9) and shaped to conform to the negative impression of the desired component. Molten metal is then poured into the sand mold; upon solidification, the metal has the geometry of the desired component.

Advantages of this process include the fact that nearly all cast alloys can be poured into sand, it is the only method for high-melting-point alloys, thin-wall sections (<4mm) can be obtained, castings can be made in a wide range of weights (grams to tons) and production volumes (one to millions), and it is the most easily scalable of the casting processes.

Some limitations of sand casting include the fact that high volume production requires a large investment in automated mold/core making and assembly equipment as well as floor space. Additionally casting yields are often less than 50%, requiring a larger amount of machining and finishing prior to use. Metallurgically cooling rates in sand castings are often slow, especially in thick sections; this often yields lower mechanical properties and higher amounts of porosity. Further, sand issues are important considerations, including the consistency and quality of the sand, the volume of the sand used (up to 1020 the weight of part), and sand removal, disposal, and/or recycling.

Sand casting is the process of choice for many large powertrain components, including blocks, heads, and intake manifold. Sand castings are less common in structural applications, due to their slower cooling rate and generally coarser microstructure. However, in certain applications, such as the cast 356-T6 nodes for the Ford GT spaceframe, need for specific geometries at low production volumes requires the use of sand castings. Other expendable mold processes, such as investment casting and lost foam casting will not be discussed, since their use for structural components is limited to special, small-volume production components.

Sand casting can produce aluminum blocks like those of cast iron. A typical resin bonded mold is shown in Fig.2.36. In comparison with cast iron, sand casting of aluminum is not so easy because oxide entrapment and shrinkage defects are likely to occur. Cast iron does not cause this type of problem. Expansion during solidification due to the formation of graphite has made cast iron ideal for the economical production of shrinkage-free castings. Sand casting using resin bonded sand is normally used for aluminum.

The Cosworth process39 is a low-pressure sand casting process used to obtain sound castings. An electro-magnetic pump fills molten aluminum from the bottom of the resin bonded mold. Large cylinder blocks have been produced using this method. Core package system40 is a sand casting process proposed by Hydro Aluminum. A chemically bonded mold uses a bottom pouring plan and the mold is inverted after pouring. This inversion positions the runner portion at the top of the casting. Then the slowly solidifying runner portion feeds melt during solidification, which generates a porosity-free cylinder block.

Sand casting is a process where molten metal is cast in a mould made from a sand mixture. In the past, the process was cost effective only for small volume production. But nowadays it is also suitable for high volume production thanks to automated equipment for making sand moulds. Sand castings generally have a rough surface sometimes with surface impurities, and surface variations. Medium to large parts such as valve bodies, crankshafts and engine blocks are typically manufactured by this process. The dimensional accuracy and surface finish of the casting depend on the type of sand and the moulding process. There are two main types of sand used for moulding: green sand and dry sand. Green sand consists of silica sand, clay, moisture and other additives. Dry sand is a mixture of sand and fast curing adhesive. When dry sand is used, it is often referred to as no bake mould casting or air set sand casting. Castings made from coarse green sand typically have a rough surface whilst air-set moulds can produce castings with much smoother surfaces.

A schematic diagram for the sand casting process is shown in Fig.6.5. A pattern is made in the shape of the desired part, but enlarged to account for shrinkage and machining allowances in the final casting. The pattern is typically made from wood or plastic, and can be reused to produce new sand moulds. Sand cores can be used to form the inside shape of hollow parts of the casting. A metal box (the flask) is used for making the sand mould. It typically consists of two halves to form the top and bottom parts of the mould, termed cope and drag respectively. The pattern is placed in the flask, and then packed with sand mixture forming a mould cavity. If necessary, a temporary plug is placed to form a channel for pouring the cast metal (so-called a sprue). After that, the pattern and channel plug are removed leaving the mould cavity and pouring channel. The cope and drag are prepared separately and assembled afterwards to form a mould. The molten metal is poured into the mould through a sprue, which transmits the molten metal via runners into the mould cavity. After the cast metal has solidified and cooled, the casting is taken out from the sand mould. Generally, no mould release agent is used and the sand mould is destroyed in the removal process. Green sand can be reused after adjusting its composition by compensating the lost moisture and additives.

Sand castings are poured into molds made of casting sand, a special sand mixture typically containing 90% silica, plus binders such as clay to hold the particles together (this is a major use of ceramics as refractories or heat-resistant materials). The first operation is to make a pattern (from wood, metal, or plastic) shaped like the required article (Figure 15.4). Sand is rammed around the pattern, and the mold is split open again to remove the pattern. Passages are then cut through the sand (by hand) for ingates and risers. The mold is reassembled and the molten metal poured into the mold cavity. When the casting has gone solid, it is removed by breaking up the (fragile) sand mold. The casting is then fettled (which involves sawing off the ingate and what is left of the metal in the feeder) before (as is often necessary) finishing critical areas (such as bolting surfaces and bores for bearings) by machining.

Even this apparently simple casting process involves a great deal of know-how and experience. The pattern must have slightly tapered sides, and a smooth shiny surface, so it can be withdrawn from the mold without pulling any sand away with it. It must also allow for thermal contraction when solid metal cools from its melting point to room temperature (patterns are generally made oversize by 12% to compensate). The shrinkage when molten metals solidify is large 3.8% for Zn alloys, 4.5% for Cu and Ni alloys, 5.7% for Mg alloys and a whopping 6.7% for Al alloys. The feeder must be able to top up the casting volume by at least this much. Obviously, the feeder must be the last part of the casting to solidify, or contraction cavities will form in unfed parts of the casting. Since the most massive part of the casting will solidify last, the feeder needs to be placed there. A useful guide to mold and feeder design is Chvorinovs rule

The mold needs to be designed so the feeder has a larger V/A than the maximum V/A for the mold cavity itself. The best shape for a feeder is a squat cylinder, which gives a large V/A. In a big or complex casting, several feeders will be needed to feed all parts of the casting adequately.

Figure 15.5 shows an example of an itema truck footstepmade by sand casting. The separate bars of the footstep have a cross section about 5mm20mm. The horizontal ridge on the centerline of the bar caused by the parting line of the original sand mold is obvious, as is the rough surface finish produced by the sand particles. The bar is cracked right through by loads applied in servicethe Al8% Si alloy used has low toughness and ductility because brittle plates of silicon are present in the as-cast microstructure (see Figure 4.6 for the AlSi phase diagram).

Sand casting is the most common method used for the production of Ni3Al-based alloy (IC-221M) components (Sikka et al., 1995; Viswanathan et al., 1997; Deevi and Sikka, 1997). The finished sand-cast components so far produced have weighed from less than 50 to 200kg, and have a varied in range of complexity. Typical foundry sands and molding procedures are acceptable for casting of nickel aluminides. The flushing of argon through the sand molds minimizes the formation of oxide skin on the cast surfaces. A computer modeling of the gating system and mold-filling orientations for nickel aluminide has been developed and experimentally verified (Viswanathan et al., 1997).

The inherent difficulty in machining nickel aluminides, lack of suitable machining tool materials, and lack of experience at the foundries, continue to make the cutting of runners and risers, grinding, machining, and weld repair of castings to be of concern for all foundries. Additional research effort is needed in the areas of cutting, grinding, drilling, and single-point machining.

Because they contain thin sections, centrifugal casting is the most economical method for the production of nickel aluminide for applications such as thin-wall (6mm) radiant burner tubes for efficient heat transfer, steel plate austenization rolls (350425mmOD25mm wall4m length), steel continuous casting guide rolls (75150mmOD25mm wall), and steel strip hydrogen annealing furnace seals and rolls (150200mmOD1225mmwall). Centrifugal castings of nickelaluminide alloys of all the size ranges listed above have been commercially cast by using conventional mold washes and parameters similar to those for commonly used alloys for similar applications. The surface quality of nickelaluminide castings is similar to that of conventional alloys.

However, the inner diameter tubes of Ni3Al-based alloys tend to contain oxide particles of ZrO2 and Al2O3. The appearance of such oxides in Ni3Al-based alloy tubes results from the presence of stable oxide-forming elements such as zirconium and aluminum, which are not present in the conventional alloys. The presence of ZrO2 and Al2O3 particles on the inner diameter has no influence on the performance of centrifugal tubes of Ni3Al-based alloys for furnace roll applications. However, the presence of ZrO2 and Al2O3 particles does cause some difficulty in machining of inner surfaces, as required for assembly of components. This problem with oxide particles has also been manifested in investment cast turbocharger wheels, and has limited the application of these alloys (Sikka, 1996).

Other than difficulties in cutting and machining, the centrifugal casting process for nickelaluminide alloys is well established for commercial production. The primary manufacturers of centrifugally cast tubes and pipes in the United States are AEC and Sandusky.

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DongYue Machinery Group, established in June 2012, including Dongyue Machinery Group Co., Ltd, Shandong National Tsing Hua University New Energy Co. Ltd, Linyi Dongyue new wall materials Co., Ltd, Linyi Dong Yue Import and Export Trading Co., Ltd, Linyi Dongyue Shengda Machinery Co., Ltd, Linyi Dongyue Pressure Vessel Manufacturing Co., Ltd totally 6 companies composition. Group registered capital of 104.1 million RMB, total assets of 724 million RMB, covers area of 500 acres, more than 2, 000 employees. It ...