[{"data":1,"prerenderedAt":-1},["ShallowReactive",2],{"detail-sidebar-cat-0-en-105":3,"doc-seo-664868-105":59,"doc-detail-664868-en":129},{"code":4,"msg":5,"data":6},0,"success",[7,13,18,23,28,33,38,43,48,51,55],{"id":8,"doc_module":4,"doc_module_name":9,"category_name":10,"show_sort_weight":11,"slug":12},1,"Document","Story & Novel",90,"story-novel",{"id":14,"doc_module":4,"doc_module_name":9,"category_name":15,"show_sort_weight":16,"slug":17},2,"Literature",80,"literature",{"id":19,"doc_module":4,"doc_module_name":9,"category_name":20,"show_sort_weight":21,"slug":22},4,"Exam",70,"exam",{"id":24,"doc_module":4,"doc_module_name":9,"category_name":25,"show_sort_weight":26,"slug":27},5,"Comic",60,"comic",{"id":29,"doc_module":4,"doc_module_name":9,"category_name":30,"show_sort_weight":31,"slug":32},6,"Technology",50,"technology",{"id":34,"doc_module":4,"doc_module_name":9,"category_name":35,"show_sort_weight":36,"slug":37},7,"Healthcare",40,"healthcare",{"id":39,"doc_module":4,"doc_module_name":9,"category_name":40,"show_sort_weight":41,"slug":42},8,"Research & Report",30,"research-report",{"id":44,"doc_module":4,"doc_module_name":9,"category_name":45,"show_sort_weight":46,"slug":47},9,"Religion & Spirituality",20,"religion-spirituality",{"id":46,"doc_module":4,"doc_module_name":9,"category_name":49,"show_sort_weight":46,"slug":50},"World Cup","world-cup",{"id":52,"doc_module":4,"doc_module_name":9,"category_name":53,"show_sort_weight":52,"slug":54},10,"Lifestyle","lifestyle",{"id":56,"doc_module":4,"doc_module_name":9,"category_name":57,"show_sort_weight":24,"slug":58},19,"General","general",{"code":4,"msg":60,"data":61},"ok",{"site_id":62,"language":63,"slug":64,"title":65,"keywords":66,"description":67,"schema_data":68,"social_meta":122,"head_meta":124,"extra_data":126,"updated_unix":128},105,"en","metal-casting-manufacturing-processes-sand-casting","Metal Casting - Manufacturing Processes - Sand Casting","","Metal Casting manufacturing processes are organized by mold type and production approach, contrasting expendable mold routes—where the mold is sacrificed—with permanent mold methods that enable higher production while restricting geometry by the need to open the mold. General casting characteristics compare sand, shell, plaster, investment, die, and centrifugal processes across typical cast materials, surface finish, porosity, shape complexity, dimensional accuracy, dimensional tolerance, cost drivers, and typical lead times, production rates, and minimum quantities. Sand casting fundamentals cover why it dominates tonnage, the range of alloys it can handle, and the full step-by-step sequence for preparing molds, patterns, and pouring.",{"@graph":69,"@context":121},[70,84,104],{"@type":71,"itemListElement":72},"BreadcrumbList",[73,77,79,82],{"item":74,"name":75,"@type":76,"position":8},"https://docshare.wps.com","Home","ListItem",{"item":78,"name":9,"@type":76,"position":14},"https://docshare.wps.com/document/",{"item":80,"name":30,"@type":76,"position":81},"https://docshare.wps.com/document/technology/",3,{"item":83,"name":65,"@type":76,"position":19},"https://docshare.wps.com/document/metal-casting-manufacturing-processes-sand-casting/664868/",{"url":83,"name":65,"@type":85,"image":86,"author":91,"headline":65,"publisher":94,"fileFormat":97,"inLanguage":63,"description":67,"dateModified":98,"datePublished":98,"encodingFormat":97,"isAccessibleForFree":99,"interactionStatistic":100},"DigitalDocument",{"url":87,"@type":88,"width":89,"height":90},"https://docshare.wps.com/thumbnails/metal-casting-manufacturing-processes-sand-casting/664868.png","ImageObject",300,407,{"name":92,"@type":93},"vwvw","Person",{"url":74,"name":95,"@type":96},"DocShare","Organization","application/pdf","2026-10-29",true,{"@type":101,"interactionType":102,"userInteractionCount":19},"InteractionCounter",{"@type":103},"ViewAction",{"@type":105,"mainEntity":106},"FAQPage",[107,113,117],{"name":108,"@type":109,"acceptedAnswer":110},"What distinguishes expendable mold processes from permanent mold processes?","Question",{"text":111,"@type":112},"Expendable mold processes sacrifice the mold to remove the part, allowing more complex shapes but often limiting production rates due to mold-making time. Permanent mold processes use metal molds that support higher production rates but restrict geometry because the mold must be opened.","Answer",{"name":114,"@type":109,"acceptedAnswer":115},"What makes sand casting widely used?",{"text":116,"@type":112},"Sand casting is the most widely used casting process and accounts for a significant majority of total tonnage cast. Nearly all alloys can be sand cast, including high-melting-temperature metals such as steel, nickel, and titanium.",{"name":118,"@type":109,"acceptedAnswer":119},"What are the main steps in sand casting preparation before pouring?",{"text":120,"@type":112},"The process includes placing and packing sand around the pattern, adding vent holes and gating components, separating cope and drag, preparing mold surfaces with coating material, assembling the mold for pouring, and ensuring proper gating and riser setup before the metal is poured.","https://schema.org",{"og:url":83,"og:type":123,"og:title":65,"og:site_name":95,"og:description":67},"article",{"robots":125,"canonical":83},"index,follow",{"doc_id":127,"site_id":62},664868,1793276751,{"code":4,"msg":5,"data":130},{"doc_id":127,"user_id":131,"nickname":92,"user_avatar":132,"doc_module":4,"category_id":29,"category_name":30,"doc_title":65,"doc_description":67,"doc_content":133,"file_id":134,"file_url":135,"file_type":136,"file_size":137,"view_count":19,"is_deleted":4,"is_public":8,"is_downloadable":8,"audit_status":8,"page_count":138,"language":139,"language_code":63,"site_id":62,"html_lang":63,"table_of_contents":140,"faqs":141,"seo_title":142,"seo_description":67,"update_tm":128,"read_time":143},3985747874149,"https://ap-avatar.wpscdn.com/avatar/3a001161165b4dc3d9e?x-image-process=image/resize,m_fixed,w_180,h_180&k=1790129441039064114","Metal Casting  \nManufacturing Processes  \nOutline  \n Sand Casting  \n Shell Mold Casting  \n Composite Molds  \n Expendable Pattern Casting  \n Plaster Mold Casting  \n Ceramic Mold Casting  \n Investment Casting  \n Pressure Casting  \n Vacuum Casting  \n Die Casting  \nCentrifugal Casting  \n Squeeze Casting and Semisolid Metal Forming  \n Casting Single Crystals  \n Rapid Solidification  \n Melting  \n Design Considerations  \nTwo Categories of Casting Processes  \nExpendable mold processes-mold is sacrificed to remove part  \n􀂃 Advantage: more complex shapes possible  \n􀂃  Disadvantage: production rates often limited by time to make mold rather than casting itself  \nPermanent mold processes-mold is made of metal and can be used to make many castings  \n􀂃 Advantage: higher production rates  \n􀂃  Disadvantage: geometries limited by need to open mold  \nGeneral Characteristics of Casting  \n\n|  | Sand | Shell | Evaporative pattern | Plaster | Investment | Permanent\u003Cbr>mold | Die | Centrifugal |\n| --- | --- | --- | --- | --- | --- | --- | --- | --- |\n| Typical materials cast | All | All | All | Nonferrous\u003Cbr>(Al, Mg,\u003Cbr>Zn, Cu) | All | All | Nonferrous\u003Cbr>(Al, Mg,\u003Cbr>Zn, Cu) | All |\n| Weight (kg): |  |  |  |  |  |  |  |  |\n| minimum | 0.01 | 0.01 | 0.01 | 0.01 | 0.001 | 0.1 | \u003C 0.01 | 0.01 |\n| maximum | No limit | 100+ | 100+ | 50+ | 100+ | 300 | 50 | 5000+ |\n| Typ. surface finish (µm Ra ) | 5-25 | 1-3 | 5-25 | 1-2 | 0.3-2 | 2-6 | 1-2 | 2-10 |\n| Porosity1 | 3-5 | 4-5 | 3-5 | 4-5 | 5 | 2-3 | 1-3 | 1-2 |\n| Shape complexity1 | 1-2 | 2-3 | 1-2 | 1-2 | 1 | 2-3 | 3-4 | 3-4 |\n| Dimensional accuracy1 Section thickness (mm): | 3 | 2 | 3 | 2 | 1 | 1 | 1 | 3 |\n| minimum: | 3 | 2 | 2 | 1 | 1 | 2 | 0.5 | 2 |\n| maximum: | No limit | — | — | — | 75 | 50 | 12 | 100 |\n| Typ. dimensional tolerance | 1.6-4\u003Cbr>(0.25 for\u003Cbr>small) | ±0 .003 |  | ±0 .005 −\u003Cbr>0.010 | ±0 .005 | ±0 .015 | ±0 .001 −\u003Cbr>0.005 | ±0 .015 |\n| Cost1 ,2 |  |  |  |  |  |  |  |  |\n| Equipment | 3-5 | 3 | 2-3 | 3-5 | 3-5 | 2 | 1 | 1 |\n| Pattern/die | 3-5 | 2-3 | 2-3 | 3-5 | 2-3 | 2 | 1 | 1 |\n| Labor | 1-3 | 3 | 3 | 1-2 | 1-2 | 3 | 5 | 5 |\n| Typical lead time2 ,3 | Days | Weeks | weeks | Days | Weeks | Weeks | Weeks\u003Cbr>months | Months |\n| Typical production rate2 ,3 | 1-20 | 5-50 | 1-20 | 1-10 | 1-1000 | 5-50 | 2-200 | 1-1000 |\n| Minimum quantity2 ,3 | 1 | 100 | 500 | 10 | 10 | 1000 | 10,000 | 10-10,000 |\n| Notes:\u003Cbr>1. Relative rating, 1 best, 5 worst. For example, die casting has relatively low porosity, mid-to low shape complexity, high dimensional accuracy, high equipment and die costs and low labor costs. These ratings are only general; significant variations can occur depending on the manufacturing methods used.\u003Cbr>2. Data taken from Schey, J.A. , Introduction to Manufacturing Processes, 3rd ed, 2000.\u003Cbr>3. Approximate values without the use of rapid prototyping technologies. |  |  |  |  |  |  |  |  |\n\nTABLE 5.2 General characteristics of casting processes.  \nManufacturing Processes for Engineering Materials, 5th ed. Kalpakjian • Schmid  \n© 2008, Pearson Education  \nISBN No. 0-13-227271-7  \nTypical Casting Metals  \nAluminum Aluminum-silicon alloy Aluminum-copper Brass  \nGray cast iron Copper  \nLead Steel  \nOverview of Sand Casting  \nMost widely used casting process, accounting fora significant majority of total tonnage cast  \nNearly all alloys can be sand casted, including metals with high melting temperatures, such as steel, nickel, and titanium  \nCastings range in size from small to very large Production quantities from one to millions  \nSteps in Sand Casting in detail  \n1. Place pattern on molding board.  \n2. Place drag parting surface down on molding board.  \n3. Riddle sand over pattern until covered.  \n4. Press sand around pattern with fingers.  \n5. Completely fill drag with sand.  \n6. Use a ram to pack sand.  \n7. Remove excess sand with strike rod.  \n8. Make vent holes for gases to escape.  \n9. Place bottom board on drag.  \n10. Turn over drag and remove molding board.  \n11. Smooth molding s","cbCainfXSFQ70dcz","https://ap.wps.com/l/cbCainfXSFQ70dcz","pdf",7480558,54,"English","# Outline\n## Sand Casting\n## Shell Mold Casting\n## Composite Molds\n## Expendable Pattern Casting\n## Plaster Mold Casting\n## Ceramic Mold Casting\n## Investment Casting\n## Pressure Casting\n## Vacuum Casting\n## Die Casting\n## Centrifugal Casting\n## Squeeze Casting and Semisolid Metal Forming\n## Casting Single Crystals\n## Rapid Solidification\n## Melting\n## Design Considerations\n## General Characteristics of Casting\n## Two Categories of Casting Processes\n## Making the Sand Mold\n## The Pattern\n## Types of Patterns","[{\"question\":\"What distinguishes expendable mold processes from permanent mold processes?\",\"answer\":\"Expendable mold processes sacrifice the mold to remove the part, allowing more complex shapes but often limiting production rates due to mold-making time. Permanent mold processes use metal molds that support higher production rates but restrict geometry because the mold must be opened.\"},{\"question\":\"What makes sand casting widely used?\",\"answer\":\"Sand casting is the most widely used casting process and accounts for a significant majority of total tonnage cast. Nearly all alloys can be sand cast, including high-melting-temperature metals such as steel, nickel, and titanium.\"},{\"question\":\"What are the main steps in sand casting preparation before pouring?\",\"answer\":\"The process includes placing and packing sand around the pattern, adding vent holes and gating components, separating cope and drag, preparing mold surfaces with coating material, assembling the mold for pouring, and ensuring proper gating and riser setup before the metal is poured.\"}]","Metal Casting - Manufacturing Processes - Sand Casting | PDF",136]