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Green Sand Casting
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Sand Casting and Green Sand Molding, generally, can be thought of as interchangeable terms, for the same Process.
The Sand Casting Process - or Green Sand Molding Process - is the most commonly used Casting Process. The alloys used most in Green Sand / Sand Castings, are aluminum, brass/bronze, and iron products.
The term "green sand" is known principally because of the moisture content within the sand. The sand undergoes a "mulling" process in which various clay and chemical additives that act as binders are blended with the sand, which results in a compound which is suitable for the sand molding process.
This prepared sand mixture is then compressed around the pattern at specific pressures and temperatures, to ensure it will maintain its shape throughout the remainder of the casting process. The blended sand and binders are compacted around the pattern, taking on the shape of the desired casting.
Sometimes the design of the casting entails internal passageways being formed into the mold. This is done by using sand cores which are made of a similar sand mixture. The cores are strategically placed to form the necessary passageways in the casting. The two halves of the mold are subsequently closed and metal is poured into the cavity and left to solidify.
After solidification has taken place, the sand is vibrated until it is released from the casting. The finishing process can then be completed by grinding, machining, plating and painting.
The below text refers to Pictures:
Moist, clay-bonded "Green*" sand is tightly packed around wood or metal patterns in mold boxes. The pattern halves are removed, and the two mold halves are assembled with or without cores.
* The term "green" denotes the presence of moisture in the molding sand, and indicates that the mold is not baked or dried.
This picture is the actual Lower half [ drag] of sand casting mold.
In this picture, both Copes and Drags are together, the Pattern rests in the sand contained inside cope and drag assembly; all completing the sand mold, and molten metal is about to be poured.
This is Green Sand.
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