THE

SAND
PROCESS
 HOW IT WORKS

The Sand Casting ( Green Sand ) molding process utilizes a cope ( top half ) and drag ( bottom half ) flask
set-up. The mold consists of sand, ( usually silica ), clay and water. When the water is added it develops the
bonding characteristics of the clay, which binds the sand grains together. When applying pressure to the
mold material it can be compacted around a pattern, which is either made of metal or wood, to produce a
mold having sufficient rigidity to enable metal to be poured into it to produce a casting. The process also
uses coring to create cavities inside the casting. After the casting is poured and has cooled the core is
removed.

The material costs for the process are low and the sand casting process is exceptionally flexible. A number
of metals can be used for castings in sizes from ounces to many thousand pounds. The mold material is
reclaimable, with between 90 and 95% of the sand being recycled, although new sand and additions are
required to make up for the discarded loss. These features, combined with the relative ease of mold
production, have ensured that the green sand molding process has remained as the principal method by which
castings are produced.

THE SAND
The sand used for green sand molding is critical and determines the favorable or unfavorable outcome of the
casting. It controls the tolerances, surface finish and the repeatability while in production. Remembering
that the tolerances on sand castings are usually wider than the other casting methods.

The sand must exhibit the following characteristics:

FLOWABILITY: The ability to pack tightly around the pattern.

PLASTIC DEFORMATION: Have the ability to deform slightly without cracking so that the pattern
can be withdrawn.

GREEN STRENGTH: Have the ability to support its own weight when stripped from the pattern, and
also withstand pressure of molten metal when the mold is cast.

PERMEABILITY: This allows the gases and steam to escape from the mold during casting.

All of these requirements are dependent on the amount of active clay present and on the water content of the
mixture.

For more information or a competitive quote please contact:

TOM CLARK
McCann Sales, Inc. Ph: 207-439-3747
E-mail: [email protected]
 SAND CASTING BENEFITS

Least Expensive Casting Process

Castings can be up to Several Tons

Less Expensive than Machining Shapes from Bar Stock

Can Cast Intricate Shapes

Can be Used with Most Pourable Metals and Alloys

SHRINKAGE ALLOWANCE FOR METALS

COMMONLY USED IN SAND CASTING

Gray Iron .83 – 1.3

Ductile Iron .83 – 1.3
Mallable Iron .78 – 1.3
White Iron 2.1
Aluminum Alloys 1.3
Magnesium Alloys 1.3

For more information or a competitive quote please contact:

TOM CLARK
McCann Sales, Inc. Ph: 207-439-3747
E-mail: [email protected]
 THE SAND PROCESS

The cope and drag are then

The pattern first makes an
combined and are ready to
impression in the cope and
accept the metal.
drag. The impression created
includes the gating system as

The metal is heated and

prepared metallurgically. It The molten metal is then poured
is transferred to a crucible into the mold.
just before pouring.

The part is the

The part is allowed to sit and The casting is then
cleaned and ready
cool. Once cooled the sent to the finishing
to ship.
casting and gating system are department where any
removed from the mold and remains of the gates
the sand is recycled. are ground off.

For more information or a competitive quote please contact:

TOM CLARK
McCann Sales, Inc. Ph: 207-439-3747
E-mail: [email protected]
 SAND CASTING

This picture shows

the cross section of a
sand casting mold.

DEFINITIONS
1. POURING CUP: This is where the metal is poured into the mold.

2. SPRUE: The vertical channel from the top of the mold to the gating and riser system. Also, a
generic term used to cover all gates, runners and risers.

3. RUNNER: The portion of the gate assembly that connects the sprue to the casting in gate or riser.

4. GATE: The end of the runner in a mold where molten metal enters the mold cavity.

5. RISER: A reservoir of molten metal provided to compensate for the contraction of the metal as it
solidifies.

6. MOLD CAVITY: The impression in a mold produced by the removal of the pattern. When filled
with molten metal it forms a casting.

7. COPE: Upper or top most section of a flask, mold or pattern.

8. PARTING LINE: A line on a pattern or casting corresponding to the separation between the parts
of a mold.

9. DRAG: Lower or bottom section of a flask, mold or pattern.

For more information or a competitive quote please contact:

TOM CLARK
McCann Sales, Inc. Ph: 207-439-3747
E-mail: [email protected]
 MECHANICAL PROPERTY LIMITS FOR COMMONLY USED
SAND CASTING ALLOYS
Alloy Temper Ultimate ( ksi) Yield (ksi) % Elongation Hardness
1000 PSI .2% offset Brinell

356 F 19 -- 2 40 - 70
356 T51 23 16 -- 45 - 75
356 T6 30 20 3 55 - 90
356 T7 31 29 -- 60 - 90
A356 T6 34 24 3.5 70 - 105

319 F 23 13 1.5 55 - 85
319 T5 25 -- -- 65 - 95
319 T6 31 20 1.5 65 - 95

85-5-5-5 F 37 17 30 60

Cast Iron F 31 -- -- 201

Note: The above properties are believed to be correct, but are not warranted in any way by McCann Sales, Inc. “F” as cast condition

GENERAL DESIGN DATA

SIZE RANGE: Ounces to tons METALS: Most all Castable Alloys

TOLERANCES: +/- 1/32” to 6” then add +/- .003/ inch PARTING LINE SHIFT: +/- .020” to .060”

AVERAGE TOOLING COST: $ 1,000 to $ 6,000 TYPICAL ORDER QUANTITY: All

AVERAGE TOOLING LEADTIME: 2 to 6 weeks SURFACE FINISH: 250 to 500 RMS

MINIMUM SECTION THICKNESS: .125 “ MINIMUM DRAFT REQUIRED: 2 to 5 degrees

Note: The above information is meant to be a basic guideline for comparison purposes only.

For more information or a competitive quote please contact:

TOM CLARK
McCann Sales, Inc. Ph: 207-439-3747
E-mail: [email protected]
 MECHANICAL PROPERTY LIMITS FOR COMMONLY USED
CASTING ALLOYS
Alloy Temper Ultimate ( ksi) Yield (ksi) % Elongation Hardness
1000 PSI .2% offset Brinell

A 365 T6 34 24 3.5 70 - 105

410 F 95 75 8 94 - 100

304 F 65 30 30 --

D-2 F 23 13 1.5 55 - 85

85-5-5-5 F 37 17 30 60

Note: The above properties are believed to be correct, but are not warranted in any way by McCann Sales, Inc. “F” as cast condition

GENERAL DESIGN DATA

SIZE RANGE: Up to 250 lbs. METALS: All

TOLERANCES: +/- .005” for 3” then add +/- .003 inches/inch

PARTING LINE SHIFT: N/A

AVERAGE TOOLING COST: $ 2,000 to $ 9,000 TYPICAL ORDER QUANTITY: All

AVERAGE TOOLING LEADTIME: 6 to 8 weeks SURFACE FINISH: 60 to 90 RMS

MINIMUM SECTION THICKNESS: .060” premium / .080” average

MINIMUM DRAFT REQUIRED: Zero

Note: The above information is meant to be a basic guideline for comparison purposes only.

For more information or a competitive quote please contact:

TOM CLARK
McCann Sales, Inc. Ph: 207-439-3747
E-mail: [email protected]