Green Sand Molding: for Proven, Affordable, Renewable Castings
Do you need strong, reliable aluminum parts? Do you need a fast and consistent production rate? Then green sand molding may be the solution to your problem! Green sand mold casting is a tried-and-true method of metal casting that has been an industry standard for nearly a hundred years – and has been a staple of our operation for just as long.
Manual green sand molding was the foundation of our operation when we began in 1933. This process is still in use today as it offers our customers low tooling costs coupled with economical casting prices. We have automated and improved since those days, building upon our experience and introducing modern developments. We have numerous flask sizes, so if you have existing tooling, odds are we have the capability to use it.
BAF also operates a 20 X 24 automatic molding machine to meet your high-production demands.
Why Choose Green Sand Molding For Your Casting Needs?
Your metal parts need to be created to strict specifications, but they also need to be made quickly. You can’t rely on die-casting, which is susceptible to defects, investment casting is labor-intensive and expensive, and dry sand molding involves long baking times. Green sand molding can provide consistently high-quality metal castings while staying well within budget. This method of metal casting results in a highly detailed product with minimal tooling.
The green sand molding process is also distinctly economical and flexible. We have specialized equipment that can produce upwards of 100 molds per hour, ensuring large-scale orders can be filled on time. The large plate size allows the machine to handle a wide array of green sand molds and tackle nearly any project.
Boose Aluminum’s Green Sand Molding Process
Green sand molding utilizes a compound mixture of sand and clay. Typically, this mixture is 80% sand and 10% clay, with water and filler material filling the last of the weight. The green sand molding process makes use of how flexible and shapable this mixture is while still maintaining high heat tolerance and allowing gases to escape.
To turn that sand mixture into a casting, we place the pattern on the first half of a two-part frame, or flask. Then we place the second part of the flask on top of the pattern. The operator fills the top half of the flask with sand, packs it, and strikes off the excess.
We flip the flask and fill the other side with sand. A column, or sprue, is cut into the sand. This will serve as the entryway when we pour molten metal into the casting.
The operator lifts off the mold, removes the pattern, inserts cores if necessary, and brings the two mold halves back together. The internal void that remains will be filled with molten aluminum resulting in a raw casting.
After pouring the molds and test bars, we knock out any cores and the green sand mold casting moves to the finishing department.
Manufacturing Highlight: 20 X 24 Hunter Automatic
You want assurance that our production will be working with the best tools possible. The Hunter 20X24 is a workhorse in the industry, and we make regular use of its high-capacity throughput. This device allows quick pressing, rotating, and cooling of aluminum castings. Just one of these machines can process upwards of 100 green sand castings per hour.
This piece of machinery is especially useful for industrial-sized orders but is not limited to them. The sizable flask is optimal for castings of up to 20 pounds. This size allows a wide array of moldings to be made at scale, from medical equipment to railway parts and everything in between. These flasks can make use of pre-existing plates, or match a plate molding.
The Hunter 20X24 is made with linear bearings and magnetic rodless cylinders instead of traditional wheels, tracks, and rails. Additionally, a digital compaction system alongside an autolock hydraulic pattern clamping system streamlines the molding process, eliminating some of the lengthy manual intervention required for mold production. Together, all these design features result in a device that is far more energy efficient, requires fewer maintenance stops, and provides heightened productivity.
The Hunter 20X24 is one of the newest additions to our process, installed on our production line in November of 2023. This device has become invaluable for quickly producing quality castings in mid- to high-volume orders. Our commitment to quality and service has never wavered, and our integration of new tools and processes has only improved our reputation.
From the Very Start, Quality Matters at Boose
We start with the highest quality sand to create moldings that will create the highest quality aluminum castings. Foundry molding sand requires very specific ratios of sand, clay, water, and filler materials. Generally, green sand in foundry mixtures is made of 80% sand, 10% clay, and 5% water, with a final 5% made up of assorted materials.
The green sand casting process is sustainable and economical. Though green sand for casting can be safely re-purposed after use, spent casts cannot be re-used. This is due to moisture loss and the decay of the rough surface after the molten metal is poured. Our mold sand mixture is tested throughout the day to ensure optimal molding conditions—because we know that what we cast matters.
