8 March 2017

Advantages and disadvantages of sand casting

Sand casting is the most popular casting process among all of the casting process. Typically relies on silica-based materials. Casting sand consists of finely ground, spherical grains that can be tightly packed together into a moulding surface. The casting designed to reduce tearing, cracking by allowing a moderate degree of flexibility and shrinkage during the cooling phase. Many automotive products, such as housings, engine blocks are manufactured by this process. Let us have a deep insight into the advantages and disadvantages of sand casting to know more about it. 

Advantages of sand casting:

  • Almost all types of alloys can be cast by this process as they melt and are pourable. 
  • Sand casting is the cheapest methods of manufacturing. As the cost of equipment is low because only sand and reusable patterns are involved. 
  • The tooling required for the casting process is relatively simple and inexpensive.
  • Any component with a complex shape can be cast easily even large components too.
  • Creep-resistant metal-based alloys for gas turbines are not mechanically workable and can only be cast.
  • Dimensional accuracy in the range of +-0.8 to 3.2 mm. 
  • Sand casting can be used to produce virtually any size part from a piston trigger to an engine block.
  • The process is highly adaptable and can be used for mass production. 
  • The lead time to make the mould short, and making sand casting ideal for short production runs. Therefore, a high production rate. 
  • This process creates an isotropic structure. 

Disadvantages of sand casting: 

  • A lower degree of accuracy than an alternate method. 
  • This process tends to yield products that have a comparatively rough surface finish.
  • Low material strength due to porosity. 
  • Surface finish dimensional accuracy is very poor. 
  • Defects such as shrinkage, porosity, surface defect, pouring metal defects are unavoidable. 
  • The secondary machining process is required if close tolerance is required. 
  • Due to it is backing process, use the extra time, labour. 
  • This process is now suitable for large with heavy size casting as they are hard to back.

Thus, sand casting process may be a cheaper alternative to investment casting and can provide much more complex shapes, get the same accuracy, finish, and overall part quality. 

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