No-Bake Molding: Where our Largest Aluminum Castings are Crafted
The largest aluminum castings we produce come out of the no-bake molding department. We can produce all types of shapes and weights, but most no-bake castings weigh between 50 and 800 pounds.
Our continuous quality checks and practices throughout the no-bake production process (including dog bones, tensile sand testing, mixer calibration, and detailed molding instructions) help to create the highest-quality no-bake castings.
What Happens During No-Bake Molding?
Each no-bake mold is formed using cope and drag patterns. The sand that fills the patterns is heated to an optimum temperature so that it will cure consistently, for the best mold strength. We then use a high-speed, high-intensity mixer to combine the sand with a chemical binder and catalyst. This sand mixture is dropped into the pattern, hand-tucked around tooling features and compacted.
After the sand hardens to a concrete-like consistency, we strip off the mold and join the halves. Then we thoroughly inspect to ensure that molten metal will flow into the mold cavity unhindered and that the metal will solidify properly during pouring.
After pouring the mold and test bars, we knock the casting out of the mold, and it moves onto the finishing department.