We Are a Leading Aluminum Sand Casting Parts Manufactuer In China

Aluminum Sand CastingDolin started aluminum sand casting in the year when our foundry was set up in 1998. After 20 years development, we have 5 green sand casting lines and 2 resin sand casting lines, which enable us produce various aluminum casting parts with weight ranging from several kilograms to hundreds kilograms. The biggest sand cast aluminum part we produced reaches to 600KG. Our aluminum sand castings span many industries as automobile, valve/pump, lighting, furniture, architecture etc., and most of our products are exported to America, Europe, Australia and Asia Market.

What makes us as a prominent and advanced aluminum casting manufacturer among our competitors is the ability of mold designing and fabrication, which allows us good management of quality and short lead time within 2 weeks compared to 3-4 weeks of our rivals.

For aluminum sand casting parts with simple geometry, our well-trained and experienced casting engineers are able to predict and avoid possible defects by optimizing pouring system, vents and risers with rich experience. For aluminum sand casting parts with complex geometry, our casting engineers will do numerical computer simulation with software Flow 3D, through which the possible defects will be forecasted. The result of the simulation allows us to optimize the designs, enhance production efficiency as well as reduce cost.

-Our Material Scope for Aluminum Sand Casting Parts

  • ASMT Standard: A319, A356, A357, A413
  • GB Standard: ZL101, ZL101A, ZL102, ZL107
  • BS Standard: LM6, LM20, LM25
  • EN Standard: EN AC-42100, EN AC-42200, EN AC-43000, EN AC-43200, EN AC-43300, EN AC-43400, EN AC-44200, EN AC-44300, EN AC-46000, EN AC-46200

What Is Aluminum Sand Casting Process?

Sand casting was invented by ancient Chinese, originated in South & North Dynasty, more than 1600 years ago, and large-scale application started from Tang Dynasty until nowadays. The invention of sand casting is as important as four-great-invention of China, and established the foundation for the development of modern industry.

Sand casting is a thermoforming process through which castings are manufactured by pouring molten metal liquid into sand mold. Sand casting utilizes expendable and reusable sand to produce castings with complex geometry and structure, making itself the most basic casting process, and more than 70% casting components are produced via sand casting globally. It’s suitable for both ferrous metal (such as iron, steel) and almost all nonferrous metal (such as aluminium, brass, titanium, nickel).

Mold material for sand casting mainly consists of sand and binder. There are 2 basic approaches of sand casting: green sand casting and resin sand casting. Green sand consists of sand, clay and moisture, which is the most popular process in sand casting, and 70% sand casting is executed via green sand casting. The advantages of green sand casting are: abundant, expendable and recycled mold material; short cycle and high efficiency for mold making; environment-friendly. The disadvantages are: lower accuracy of dimension; rough surface on blanks; higher risk of defects as blowhole, pinhole, scab and cut. Resin sand consists of sand and synthetic binder cured physically and chemically. The advantages of resign sand casting are: higher accuracy of dimension; lower risk of defects as blowhole, pinhole, scab and cut. The disadvantage is: the production cost is relatively higher than green sand casting.

-Preparation For Sand Casting Process

  • aluminium sand casting process illustrationMaking Patterns and Core Box
    Fabricate patterns and core boxes according to the designing of sand casting. The material of patterns and core boxes is made of wood, plastic or metal. Patterns are used to make sand mold as drag and cope, while core boxes are used to make sand cores.
  • Mold Sand Prefabrication
    Mold material for sand casting mainly consists of sand and binder. There are two kinds of mold sand: green sand and resin sand. Green sand consists of sand, clay and moisture, which is the most popular process in sand casting. Resin sand consists of sand and synthetic binder cured physically and chemically.
  • Sand Core Preparation
    Sand core is fabricated by utilizing manual labor or machine to fill the resin sand into the sand box. After sand core is solidified, open the core box and get the sand core. Sand core is used to insert the sand mold to form the inside structure of a castings.
  • Metal Smelting
    Metal smelting is carried out by utilizing smelting furnace to smelt metal alloy. The aim of smelting process is to get pure molten metal alloy with qualified chemical property and right pouring temperature.

-7 Steps To Accomplish A Typical Aluminum Sand Casting Process

Step 1: Making Drag

aluminium sand casting process step-1

Place casting flask over the drag pattern, and fill the prefabricated sand in the flask. Squeeze the sand with pestle, and strickle off the extra sand to get the drag.

Step 2: Assembling Flasks

aluminium sand casting process step-2

Turn over the drag, and assemble the cope pattern on the drag pattern with location pins. Place and locate casting flask over the cope pattern to make cope.

Step 3: Making Cope

aluminium sand casting process step-3

Fill the prefabricated sand in the flask with the pouring pins and riser pins are fixed. Squeeze the sand with pestle, and strickle off the extra sand to get the cope.

Step 4: Removing Patterns

aluminium sand casting process step-4

Disassemble cope and drag. Remove patterns, pouring pins and riser pins. Make pouring system, which includes pouring basin, sprue hole, choke, runner and gate.

Step 5: Assembling Sand Mold

aluminium sand casting process step-5

Clean up the parting plane. Insert and locate the prefabricated sand core in the drag. Assemble cope on the drag to get ready for pouring.

Step 6: Pouring & Cooling

aluminium foundry

Pour molten metal into the sand mold via pouring system until molten metal overflow from riser. The castings is cooled and solidified in the air condition.

Step 7: Demolding and Finishing

aluminium sand casting process step-7Break away the sand mold and sand core after the casting is cooled and solidified. Cut off the riser and runner on the castings. After finishing processes as heat treatment, surface treatment, CNC machining and inspection, the castings is processed to the designed component finally.

-The Advantages of Aluminum sand Casting Process

  • Mold material of sand casting process is cheap and reusable.
  • Sand casting process is suitable for both single-piece production and small-volume production.
  • Production cycle of mold for sand casting process is relatively shorter than other casting process as gravity die casting, high pressure die casting and low pressure die casting.
  • Sand casting process is suitable for castings with big size and complex geometry.
  • Sand casting process is almost suitable for all kinds of metal, and widely applied in various industries.

-The Disadvantages of Aluminum sand Casting Process

  • Labor intensive, poor working environment, low-level automation.
  • Castings produced by sand casting process is normally with low dimension accuracy, poor surface roughness and high scrap rate.