Gray Iron Sand Casting

Product Details

Gray iron sand casting is a metal casting process.

1. Due to the advantages of using internal sand core, live block shape, gasification mold and other special construction methods, castings with complex appearance can be produced;

2. The size and weight volume of castings are almost not limited, and the weight and volume of castings are usually tens of grams to hundreds of kilograms;

3. Sand casting has certain limitations on the minimum wall thickness of castings.

Pearlitic matrix gray cast iron—that is, small and uniform graphite flakes are distributed on the pearlite matrix, and its strength and hardness are relatively high.

Product Description

1. Implementation standards: The company strictly implements ISO9001 & TS 16949 certification.

2. Product material standards: ISO, GB, ASTM, SAE, ISO, EN, DIN, JIS, BS

3.Main processes: sand casting, silica sol investment casting, water glass investment casting,

shell casting,deburring, sand blasting, machining, heat treatment, leak testing, surface treatment, etc.

4. Available materials:

Gray iron: ISO standard: 100, 150, 200, 250, 300, 350

Ductile iron: ISO standard: 400-18, 450-10, 500-7, 600-3, 700-2, 800-2

— Other materials: cast iron, cast steel, cast aluminum, cast copper, alloy steel, etc. can be customized according to customer requirements.

According to the country, please check the corresponding national material grade in the table.

5. Available software: Pro/E, Auto CAD, Solidwork.

6. 2D & 3D drawings (Igs, PDF, JPEG, DWG, CAXA, UG, Stp...etc) can also be made according to samples.

7. Production process: sand casting, lost foam casting, water glass lost wax casting, silica sol investment casting, etc.

8. Product weight range: from 0.01kg to 2000kg;

Process Flow

Gray iron sand casting is the most popular and simplest type of casting that has been used for centuries. Sand casting is sand casting used to make large parts such as gray cast iron, ductile iron, stainless steel and other types of steel. The main steps include painting, moulding, core making, moulding, melting and pouring, cleaning, etc.

1. Drawing

The traditional method is to obtain casting drawings and send them to the foundry. This process can be done in the quotation. Today, more and more customers and foundries use computer-aided design instead.

2. Mould

In sand casting molds are made of wood or other metal materials. In this process, we ask our engineers to make the mold size slightly larger than the finished product, the difference is called shrinkage allowance. The purpose of which is that the molten metal acts on the mold to ensure that the molten metal solidifies and shrinks, thereby preventing voids during casting.

3. Core making

Core making is simply by placing resin grit into a mold to form a casting of the interior surface. So the void between the core and the mold ends up being the casting.

4. Forming

During the smelting and molding process, a pair of molds need to be prepared. Forming generally involves the support frame of the mold, pulling the mold to separate it during casting, melting the previously placed core in the mold and closing the mold mouth.

5. Clean

The purpose of cleaning is to remove grit, sanding, and excess metal from castings. Welding, sand removal can improve the surface appearance of the casting. Burnt sand and scale are removed to improve the surface appearance of the casting. Excess metal and other risers are removed. One step closer to welding and grinding and other steps. Finally check its defects and overall quality.

6. Organize

Reprocessing before shipment. According to the requirements of different customers, we can do heat treatment, surface treatment, additional inspection, etc.

7. Selection of pouring location

(1) The important processing surface of the casting should be facing down or on the side.

(2) The wide plane of the casting should face down.

(3) The thin-walled part with a larger area should be placed in the lower part of the mold or in a vertical, inclined position.

(4) For castings that are prone to shrinkage cavities, the thicker section should be placed on the upper or side.

(5) The number of cores should be minimized, and it is easy to place, fix and exhaust.

8. Selection of mold parting surface

(1) It is easy to start the mold and simplify the molding process.

①The selection of the parting surface should try to avoid the live block and the core, so as to simplify the molding, modeling and forming process.

② In order to facilitate the mold release, the parting surface should be selected at the source of the largest section of the casting.

③ The parting surface should be as straight as possible, and the number is small.

④ Try to make the casting have only one parting surface, so as to adopt two-box modeling with simple modeling process.

(2) Try to put the important processing surface or most of the processing surface and the processing datum surface of the casting in the same sand box.

Casting Process

1. Heat treatment: annealing, carbonization, tempering, quenching, normalizing, surface tempering

2. Processing equipment: CNC, WEDM, lathe, milling machine, drilling machine, grinder, etc.;

3. Surface treatment: powder spraying, chrome plating, painting, sandblasting, nickel plating, galvanizing, blackening, polishing, bluing, etc.

Moulds and Inspection Fixtures

1. Mold service life: usually semi-permanent. (except for lost foam)

2. Mold delivery time: 10-25 days, (according to product structure and product size).

3. Tooling and mold maintenance: Zhongwei is responsible for precision parts.

Available Materials List:

Gray iron sand casting and ductile iron castings

Other materials: cast iron, cast steel, cast aluminum, cast copper, alloy steel, etc. can be customized according to customer requirements.

Quality Control

1. Quality control: the defective rate is less than 0.1%.

2. Samples and trial run will be 100% inspected during production and before shipment, sample inspection for mass production according to ISDO standards or customer requirements

3. Testing equipment: flaw detection, spectrum analyzer, golden image analyzer, three-coordinate measuring machine, hardness testing equipment, tensile testing machine;

4. Provide after-sales service.

5. The quality can be traced back.

Scope of Application

1. Engine parts

2. Auto parts

3. Mechanical parts

4. Railway train parts

5. Truck parts

6. Tractor accessories

7. Construction equipment

8. Agricultural equipment

9. Machine tool equipment

10. Other industrial fields.

http://www.zw-metalware.com/