Sand Casting

1. Casting Patterns: The first step is to create casting patterns, which are replicas of the desired part. These patterns are typically made of wood, metal, or other materials and are used to create the mould cavity.

2. Core Making: For parts with internal features, cores are created using sand or other materials to form the desired interior shape within the mould.

3. Mould Production: Moulds are made by packing sand around the pattern to create a negative impression of the part. This mould cavity is what the molten metal will fill.

4. Furnace Charging: The selected metal alloy is melted in a furnace and brought to the appropriate pouring temperature. The furnace is charged with the correct amount of metal to match the part's size and weight.

5. Metal Pouring: The molten metal is poured into the mould cavity, typically through a sprue, which allows the metal to flow smoothly and evenly.

6. Shake Out: After the metal has solidified, the mould is broken apart, and the casting is removed. Any excess sand and other debris are shaken off.

7. Finishing: Castings often require post-processing to remove any excess material and achieve the desired surface finish. This can involve grinding, machining, or other methods.

8. Heat Treatment: Some castings undergo heat treatment to improve their mechanical properties, such as hardness or strength. This step can involve annealing, quenching, or tempering, depending on the material and part requirements.

9. Quality Control: Throughout the entire process, quality control measures are implemented to ensure that the castings meet the specified standards. This can include inspections, measurements, and non-destructive testing.

10. Dispatch: Once castings pass quality control, they are prepared for shipment to their intended destinations. This step involves packaging and logistics to get the parts to customers or assembly lines.