E-mail: dongrun@dongruncasting.com

Aluminum Sand Casting

The History of Aluminum Sand Casting in Dongrun

Aluminum Sand casting is traditional casting process in China, it is major inventions of ancient China, it is important as China's four great inventions. The sand cast process originated in the Southern and Northern Dynasties, about 1600 years ago.

Our aluminum foundry is set up in 1995 year. First, we only have green sand casting process, then We built resin sand casting line in 2000 year. Now we have five production lines for large aluminum green sand casting jobs up to 500kg/piece and 30 platforms for smaller aluminum alloy castings. Meanwhile, we have one production line for resin sand casting . We are leading in China foundries in Zhejiang province. There is green sand casting process for sand casting manufacturer, but we have two process.

We make molds in our foundry and we have a good ability in sand casting mold design, It is difficult for many China sand casting factories. So if you have decision to cooperate with us, we must be a good sand casting supplier for you and your company.

Our cast aluminum  products are exported America, Europe and Asia market, including auto components, furniture components, lighting components, pump valve components, architectural components and so on.


The Introduction : Sand Castings

Sand  casting is used to make large parts, suitable for Aluminum alloy, Iron,  Steel and Brass metal. There are two techniques: green sand casting and  resin sand casting. The sand cast molds are same for the two ways,  their difference is only sand. Green sand is for green sand casting  process, which is the most common used by foundries; resin sand is for resin sand casting process or making cores.

    ❖  The "green sand" consists of mixtures of sand, clay and moisture.

    ❖  The "resin sand" consists of sand and synthetic binders cured thermally or chemically

    ❖  The cores used for forming the inside shape of hollow parts of the casting are

As  usually, the material of sand casting moulds is wood, silica or  aluminum alloy. If the aluminum part is small, the quantity is less and  the structure of castings is easy, we make the casting parts by wood  mold or silica mold, such as furniture components, architectural components; If the structure is complex, the aluminum product is very big, or the order will be continued several, we suggest to make the sand  casting parts by aluminum alloy mold, such as engine blocks, cylinder heads, housing.

The sand mould is re-usable and permanent  patterns, there are some pouring cups and risers on the moulds. How to  set up the pouring cup and riser is the key in moulds design


 1.jpgCast Aluminum  Foundry
In Dongrun Cast Aluminum foundry, there are five large-scale Sand Casting product lines and twenty medium sand casting product platforms in the factory. We can max size 3000X3000X2000mm Sand Cast Aluminum. Our sand casting workshop is about 5000 square meters. Whatever your casting project is small or big, we can give you good lead time and good quality. In our foundry, more than 90% Cast Aluminum parts are exported. So we have much experience for your projects.
2.jpgTop Pattern And Bottom Pattern
In Dongrun Aluminum casting foundry, there are five people who are skilled pattern maker to build patterns, using wood, aluminum, or resin. As usually, 1 set mold including top pattern and bottom. If the structure of mold is very complex, there is a sliding block, named core too. Such cores, sometimes reinforced by wires, are used to create under cut profiles and cavities which cannot be molded with the cope and drag, such as the interior passages of housing or cooling passages in CAC tanks.
1.jpgSand Mould--Remove The Pattern
For our American project—flat on one side; ribs on other side, closed at the bottom and top together, be filled with prepared casting sand or green sand—a slightly moist mixture of sand and clay; The color is red, so aluminum sand casting is named green sand casting; if make cast iron, the color of sand is black, so iron sand casting is named black sand cast. The sand is packed in through a vibratory process or press process. The pattern is placed on the sand. Other sand is rammed over and around the pattern. Finally a cover is placed on the box and it is turned and unlatched, so that the halves of the mold may be parted and the pattern with its sprue and vent patterns removed. Additional sizing may be added and any defects introduced by the removal of the pattern are corrected. The box is closed again. This forms a "green" mold which must be dried to receive the hot aluminum. If the mold is not sufficiently dried a steam explosion can occur that can throw molten aluminum. Sand may also be bonded by chemical binders, such as furane resins or amine-hardened resins.

4.jpgFill The Mold Cavity With Molten Aluminum
When we make sand moulds, there are some paths for the entrance of aluminum into the mold cavity constitute the runner system and include the sprue, various feeders which maintain a good aluminum 'feed', and in-gates which attach the runner system to the casting cavity. Gas and steam generated during casting exit through the permeable sand or via risers, which are added either in the pattern itself, or as separate pieces. To be free of any porosity, we will place filter screens on the sprues.

1.jpgBreak Away The Sand Mould And Get The Aluminum Casting
When the aluminum is cool, break away the sand mold and get the aluminum casting. After Feeding, the aluminum alloy will be cool about 5-10mins. Of course, if the aluminum casting is more bigger, need more time for cooling. Please don’t break the sand mould in short time. If the time is not enough for cooling, your casting will be twisted or bended. It is very important for sand casting process.

1.jpgFinished Sand Cast Aluminum
Finishing the sand casting process, we will remove the sand on the casting by washing. After these process, the casting parts will moved to surface finished workshop. We have many skilled workers for sand casting surface. The will do grinding, polishing and shot blasting. If so, you can get clean casting with good surface. As usually some sand cast aluminum parts have to be done heat treatment and CNC machining process. However we can offer you all process services for you. From casting to machining, one stop solutions for your projects.

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