Forming metal is pretty fun! There are many types, but one popular version is 'sand casting'. That consists in the formation of a pattern with sand and pouring molten metal into that mold. The part is taken out of the sand mold once metal has cooled down. There are few pieces to this process
Reviewing the Sand Mold(csv) - The First Stage of Sand Casting
The very initial stage of sand casting is to produce the sand mold. We use foundry sand which is a particular type of because it can endure high heat melted metal. Foundry sand is combined with a binder, such as clay or water to hold the two together. Next we place the sand mixture around a pattern, which is what our metal part will be like. The pattern is a wooden or plastic replica of the exact component to be casted and, previously usedral decades were commonly employed in sand molding.
Sometimes we would like our metal part to have an inside hole (eg. cup, bowl). This allows us to do so... We need an area for the air created when we pour molten metal into a sand mold. This space is called a core. Cores: Cores are reinforced sand and binder mixtures pack into a core box. We then place the core into sand mold, and pour melted metal in it. We take the sand and core out, and then we can remove a finished part once it is removed.
Once the pattern is set in place, and we have packed our sand mix around it (and possibly added any needed cores as well), we are ready to pour the molten metal. The metal is then heated until it can be poured, and the liquid metal flows into the sand mold. This will make it difficult to fill the whole shape without including air bubbles, so pour slowly and carefully. When the metal is cooled, it become hard and we are left with a solid piece of metal.
After the metal is fully cooled, we remove the finished part from its sand mold. Typically, the mold is broken apart by either hammering it or shaking it with a machine. The part still has rough edges or some sand remains stuck to it once you have pulled it from the wet sand. We touched it up with grinder or other similar equipment, grinding down all of the edges and remaining sand.
With the sand cast part all nicely cleaned and smoothed out we just have a few more things to do before it is good for use. We might be making holes in it or sticking other parts to do with it, we may also paint this! We would then test the part to ensure that should it be used in a car engine, for example, or any airplane devices where its strength is paramount.
Finally, this process includes mold making with sand, cavity pouring poured in metal and the casting is then separated from used for purpose. Used to manufacture a wide variety of every day objects from mechanical parts. This is, really a cool process to see and learn.
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