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.