Metal Casting Zone Info Blog

Hello,

We have an exciting topic today!  It is called Casting Sand.

Sand casting is the most ancient form of metal casting and has been
around since at least Ancient Egypt. Many metal casters prefer
using sand casting over many of the other forms of processes
because it’s cheap and the sand used is readily available.

Many experienced metal casters will continue to use sand casting
even though their abilities and resources allow them to use the
other metal casting methods like Lost Wax Casting or Investment
Casting. Sand casting involves less material and less effort than
the other casting methods. Sand casting is a great way for new
casters to get into the trade.

In sand casting, the metal caster will create a mold by placing an
original in the flask which is filled with sand. The original will
be a pattern of what you want to cast. By ramming or vibrating
the sand, the caster creates a mold of the original. The casting sand
used needs to be able to retain the shape of the mold. Finding the
right mixture of sand to water is crucial. Too much water can ruin
the mold and possibly destroy it while too little water will create
a poor casting. Green sand is a type of casting sand that many
prefer since its ability to retain the shape of the mold is far
better then normal sand. Green sand usually contains bentonite clay,
sand, and water.

After the sand is packed, the pattern or original is removed carefully.
Molten metal is poured into the mold and allowed to cool. The metal
caster will then break the mold and dig out the casting.

While sand casting has its benefits the use of green sand can
greatly increase the likelihood of a successful casting. Green sand
is not really green the color refers to the damp nature of the sand.
Green sand is created by adding water and bentonite to the sand.
One of the benefits of using bentonite in green sand is that it
makes the sand more permeable which allows more gas to escape.

Metal casters can get the bentonite from a variety of sources like
home improvement stores and even from household resources. Many
have milled the type of cat litter that clumps since one of the
ingredients is bentonite. Remember to work in a well ventilated
room or to wear proper face gear when working with bentonite since
it will irritate the lungs.

There are several recipes online for green sand but the most common
method is experimentation. What you are looking for when mixing the
sand, water, and bentonite is a texture that is not wet but damp
and will retain its shape when molded.

The type of sand you use to make green sand depends on you and the
availability of the sand. Many will use sand that they found out
in the wilds of nature and some will buy bags of sand like
playground sand. As you cast with green sand you will find out
which works best with what metals.

Green sand is growing in popularity as more casters are recognizing
the properties of this method. If you have traditionally used
regular sand casting, green sand casting will prove to be easier
to work with and will produce better casts.

The best part about green sand casting is that is does not cost
a lot of green.

Here is a link to a Web Page that covers this E-Course Email:
http://www.metalcastingzone.com/casting-sand/

P.S.
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