Aluminum Sand Casting Process

Aluminum Sand Casting Process

Aluminum Sand Casting Process Manufacturer China Product Description and Process Aluminum Sand Casting Process Manufacturer China Production process: aluminum sand casting process Machining process: CNC machine, machining center, lathe, mill machine, drill machine, etc. Surface treatment...

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Aluminum Sand Casting Process Manufacturer China

Product Description and Process

Aluminum Sand Casting Process Manufacturer China

Production process: aluminum sand casting process

Machining process: CNC machine, machining center, lathe, mill machine, drill machine, etc.

Surface treatment process: anodic oxidation, Dacromet coating, powder coating etc.


Product Material and Uses

Normally produce with ZL101, ZL101A, ZL102, ZL104, ZL106, ZL107, ZL109, ASTM A356 T6, A319, A413, LM6, LM20, LM25, etc.

The aluminum casting products are widely used for electronic industry, auto-car parts, railway parts, electric motor parts, aero craft parts, watercraft parts, medical treatment equipment, communication system, other machinery components, etc.


Aluminum Sand Casting Process

Green sand, which is new or regenerated sand mixed with natural or synthetic binders, is the most commonly used material for making aluminum expendable molds.

Green sand molds get their name from the fact that they are still moist when the molten metal is poured into them. The process of aluminum sand casting using green sand and the gravity filling method can be summarized as follows: a mold is created by placing the mixture of sand, clay and water on a pattern (the replica of the object to cast). Although this process can be done by hand, machinery is normally used in order to achieve better precision of the mold. When the pattern is removed the clay will have a cavity that corresponds to the shape of the pattern.

The sand mold has two or more parts, the upper part is known as the cope while the bottom one is called the drag. Additional parts known as cheeks can also be used.

The molds are encased in a two part (or more if cheeks are used) box called a flask for protection. Before the flask is closed, any sand cores needed to manufacture the part details are placed in the mold halves. The gating system is placed inside, and a sprue is formed in order for the molten alloy to be fed into the cast.

The two halves are closed and clamped together and molten metal is then poured into the mold. As the metal starts to cool and some contraction takes place, molten metal is fed in from the risers that were placed in the casting system.

Because sand and clay do not absorb heat, the cooling time is a lot longer than that of permanent mold or die casting. Chills (metal plates) can be inserted into the sand mold in order to help provide an equal cooling rate throughout the cast. As a consequence of the slower cooling, there is an appreciable decrease in the mechanical properties of alloys such as Aluminum 319 and 356, magnesium and bronze when compared to those of the same alloys cast with the permanent or die casting methods based on the Secondary Dendrite Arm Spacing (SDAS) value.

After a preset dwell time to allow the metal to solidify, the cast shake out takes place. The heat from the molten metal that is poured into it dries out the moisture making the cast easy to crack open when the metal has cooled.

Aluminum sand casting defects to look out for are residual oxide film, inclusion, core erosion, gas holes and shrinkage porosity.

Sand cast aluminum components are widely used in the automotive and transportation industries including aerospace. Parts commonly produced with sand casting include the power-train, supports, suspensions, casings, gears and many others.


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