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?
Green sand molding can provide consistently high-quality metal castings while staying well within budget. The method of metal casting results in high quality products made with affordable tooling, when compared to die casting or permanent mold tooling costs.
At BAF, we have a variety of machines and processes that can be geared to produce low-volume runs up to 1000’s of parts, depending on your needs.
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
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.
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 high throughput ensures large-scale orders can be filled on time.
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.
