shell sand casting_shell sand casting

Sand casting is one of the oldest and most widely used casting processes in the manufacturing industry. It involves creating a mold from sand and then pouring molten grey cast iron into the mold cavity. The process begins with the preparation of a mold, which consists of two halves the cope (upper half) and the drag (lower half). The sand is mixed with a binder, usually clay, and water to create a mold that can hold its shape when the molten metal is poured.

The ability to create lightweight components is particularly significant in the face of growing regulatory pressures for fuel efficiency and lower emissions. Lighter vehicles consume less fuel and contribute to reduced greenhouse gas emissions, aligning with global sustainability goals. Die casting facilitates the use of aluminum and magnesium alloys, which are not only lightweight but also possess favorable mechanical properties, making them suitable for various automotive applications.

However, the hot chamber process has limitations, including the types of metals that can be used. High-temperature alloys (like aluminum and copper) cannot be used since they would damage the mechanical components of the casting machine.