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A molding sand mixture, usually green sand or bentonite, is blown into a rectangular steel chamber using compressed air. The molding sand is then squeezed between two patterns, which are on the two ends of the chamber. After squeezing, one of the chamber plates swings open and the opposite plate pushes the finished mold onto a conveyor.
Sand casting, also known as sand molded casting, is a metal casting process characterized by using sand—known as casting sand—as the mold material. The term "sand casting" can also refer to an object produced via the sand casting process. Sand castings are produced in specialized factories called foundries. In 2003, over 60% of all metal ...
All of these early suppliers are still in business today and continue to have close relationships with BCI. [1] In 1972, the company changed its name to Bremen Castings, Inc. [2] Starting in the mid-1990s, Bremen Castings started to expand beyond casting. The foundry's machine shop opened in 1996 and the tool shop opened in 2009. [3]
Green-sand cores. Green-sand cores makes casting long narrow features difficult or impossible. Even for long features that can be cast it still leave much material to be machined. A typical application is a through hole in a casting. [2]
The pattern is made of wax, wood, plastic, or metal. The molds are constructed by several different processes dependent upon the type of foundry, metal to be poured, quantity of parts to be produced, size of the casting, and complexity of the casting. These mold processes include: Sand casting – Green or resin bonded sand mold.
But considered "green" in the sense that it is used in a wet state (akin to green wood). According to the Cast Metals Federation website, an alternative casting method is to heat-dry the molded sand before pouring the molten metal. This dry sand casting process results in a more rigid mold better suited to heavier castings.
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For aluminum castings, sand casting represents about 12% of the total tonnage by weight (surpassed only by die casting at 57%, and semi-permanent and permanent mold at 19%; based on 2006 shipments). The exact process and pattern equipment is always determined by the order quantities and the casting design.
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