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Sand Casting
Why over 60% of all metal castings are produced via sand casting
The greatest strength of sand casting is its versatility. The process can produce castings of various size, from 1 kg to 15 tons, and can easily handle different shapes and designs (with proper casting engineering). This process also has the most flexibility in material choice. Most metals, including special steels and various alloys can be used in this process. Combined with inexpensive tooling and relatively straight-forward casting operation, this process easily becomes the go-to method for most metal casting production.
However, sand casting is also prone to porosity and other defects. Sand casting is so much more than just pouring molten metal into a sand mold. It takes years of experience to get the process right.
Quality sand casting is what we do
As a World-Class Sand Casting Engineering company, Omnidex specializes in high quality porosity-free sand casting, including heavy-duty supersized castings that is trusted by the leading mining companies around the world. As experts in Sand Casting, we understand your concerns over casting quality. That is why we strictly follow a series of industry best practices to prevent shrinking defects and porosity, and ensure the quality of our sand casting products is always up to our highest standards.
Impeccable patterns
All or our casting patterns are CNC machined with specialized equipment. Accuracy is paramount at this stage as any inaccuracy in the pattern will lead to inaccurate castings later in the casting process.
World-class sand casting engineering
Our engineering team will take into account all shrinkage allowances, draft angles and other factors when designing the mold. Placement of removable cores, feeds, uprisers, chill blocks are also carefully thought out to produce the perfect results.
State-of-the-art simulation tests
Every casting design has to go through a series of simulation tests. These tests allow our engineers to estimate the likelihood of porosity, so they can move, increase or decrease the feeds and uprisers or add chill blocks as required.
Supervised by casting veterans
Our process is supervised by our highly experienced sand casting specialists. We will take into account the metal flow in the sand mold, material cooling and other issues such as uneven shrinkage or surface distortion to produce castings of the highest quality possible.
Excellent pre-treatment and finishing
Ferrous castings are pre-treated with zinc phosphate which provides a high level of corrosion protection, and finished with anti-rust coatings, zinc plating, powder coatings or spray painting.
Pros and Cons of sand casting:
- Variable casting size (from 1 kg all the way up to 15 MT)
- Diverse range of shapes and designs
- Wide choice of materials
- Relatively inexpensive tooling
- One mold per mold box usually
- High level of waste (sand, feeds, uprisers and ballasts)
- Prone to shrinkage, porosity and pouring errors
Tolerence table
| Normal dimension (mm) | Linear dimensional tolerances (ISO8062) | |||
| ＞ | ≤ | CT9 | CT10 | CT11 |
| – | 10 | 1.5 | 2 | 2.8 |
| 10 | 16 | 1.6 | 2.2 | 3 |
| 16 | 25 | 1.7 | 2.4 | 3.2 |
| 25 | 40 | 1.8 | 2.6 | 3.6 |
| 40 | 63 | 2 | 2.8 | 4 |
| 63 | 100 | 2.2 | 3.2 | 4.4 |
| 100 | 160 | 2.5 | 3.6 | 5 |
| 160 | 250 | 2.8 | 4 | 5.6 |
| 250 | 400 | 3.2 | 4.4 | 6.2 |
| 400 | 630 | 3.6 | 5 | 7 |
| 630 | 1000 | 4 | 6 | 8 |
| 1000 | 1600 | 4.6 | 7 | 9 |
| 1600 | 2500 | 5.4 | 8 | 10 |
| 2500 | 4000 | 6.2 | 9 | 12 |
Materials
- Aluminium alloys
- Brass alloys
- Bronze alloys
- Steel
- Carbon steel
- High tensile steel
- Stainless steel
- Grey iron
- Spheroidal graphite iron
We are always ready to help with your latest project.
Contact our Customer Service and let us know how we can help to catapult your next project to success.
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Phone nos.:
Asia Pacific, South America, Africa and rest of the world: +86 20 8388 7080
UK: +44 (0)808 123 0080
USA/Canada: + 1 (800) 967 2110
Asia Pacific, South America, Africa and rest of the world: +86 20 8388 7080
UK: +44 (0)808 123 0080
USA/Canada: + 1 (800) 967 2110
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