Sand Casting

Sand Casting

Aerocast’s foundry uses the sand casting process to produce the Company’s products. Sand casting consists of the following steps:

A mixture of natural or synthetic sand combined with a binder (glue) is poured into a plastic or metal device known as a pattern. The sand mixture hardens in a short time to form a sand mould.
The pattern is turned upside down once the sand mixture has hardened and the sand mould piece is removed.
Smaller patterns known as core boxes may be used to create sand mould pieces called cores.
The entire sand mould is then assembled. Sand cores, if any, are glued in place inside the sand mould at the locations where the casting will have cavities. Finally, the top part of the mould is glued to the bottom and the mould is ready for metal pouring.
Molten metal is poured into the mould where it is allowed to cool.
After the casting has hardened, the sand is knocked out. Excess metal is cut and ground away. The casting is then sand-blasted and finished to its final or pre-final standard.
Finished castings are inspected and undergo non-destructive testing to ensure that they meet the customer’s specifications.