This process is typically used to make larger components. The molten metal is poured into a prepared cavity formed out of sand. The Green Sand Mould process - is commonly used in the casting of aluminum, brass/bronze, and iron products. The term "green sand" is known principally because of the moisture content within the sand. The sand undergoes a "mulling" process in which various clay and chemical additives that act as binders are blended with the sand, which results in a compound which is suitable for the sand molding process
Pattern Creation:- A pattern maker creates an original master pattern typically from wood, plastic or steel. For simple designs the pattern is usually in one piece. For more complex designs it is usually made in two parts. Due to shrinkage the pattern is made oversize to allow for contraction on cooling.
Mould Production:- The pattern is held in a box called a flask, this is then rammed with sand. The sand contains a binder which helps harden the sand into a semi-permanent shape. Cores, shapes from sand, are inserted into the mould to produce the internal features of the part such as holes or internal passages.
Pouring:- Simple moulds are open at the top whilst two piece moulds have an integral pouring cup connected to a sprue and gating system, Vent holes are normally required to allow hot gasses to escape and to enable good mould fill. The molten metal, ideally at least 200 degrees above the metals melting point, to ensure good fluidity, is poured into the mould.
Cleaning:- Cleaning refers to all operations necessary for the removal of sand, scale, and excess metal from the casting. After solidification has taken place, The casting is separated from the mould and transported to the cleaning department. Burned-on sand and scale are removed to improve the surface appearance of the casting. Excess metal, in the form of fins, wires, parting line fins, and gates, is removed. Castings may be upgraded by welding or other procedures. Inspection of the casting for defects and general quality is performed.
Available Materials: gray iron (from GG10 to GG35) ductile iron (from GGG40 to GGG80), brass, copper alloy, steel , stainless steel (304 316 316L ), carbon steel, alloy steel, aluminum and so on.
Available weight: from 0.2kg to 3000 kg
Most of die casting products should be processed or manufactured into components or a finished product for end using.
Available surface treatments: painting, coating, plating, hot dip galvanizing,passivation, oxidation treatment.
Main products: water pump housings, water pump impellers, auto exhaust manifolds, cylinder heads, cars, trucks, boats accessories, ,rings,seals,Hydraulic pneumatic components, valve body parts,radiator parts, compressor parts, motor subframes, bearing seats and other machine parts, These components are manufactured to out customers’ specifications provided in forms of blueprint files or samples