Sand Casting

The oldest and most versatile method for producing aluminum castings is sand casting. The process starts with two patterns: one pattern is used to form the top mold half called the “Cope”, and the other pattern is used to form the lower mold half called the “Drag”. A fine sand mixture called Green Sand is then packed tightly around the patterns.

When the patterns are removed and the two mold halves are assembled, a mold is formed into which the aluminum is poured. Sand cores can also be inserted into the mold to form hollow passageways or to cast intricate geometry that cannot be formed by the sand casting patterns.

Common sand casting applications include:

  • Air Cylinders
  • Aluminum Housings
  • Cooling Fins
  • Covers
  • Electrical Boxes
  • Electrical Transmission Equipment
  • Fans Blades & Hubs
  • Gear Boxes
  • Gear Cases
  • Hubs
  • Hydraulic Cylinders
  • Impellors
  • Manifolds
  • Marine Components
  • Oil Pans
  • Pressure Housings
  • Pump Components
  • Suspension Components
  • Transmission Channel Plates
  • Valve Bodies
  • Valve Housings
  • Wind Generation Equipment

As compared to die casting and permanent mold casting, sand casting is a slower casting process but often more economical for lower production requirements due to the low upfront investment in tooling. Sand castings have a high degree of structural integrity. Sand casting tooling is low cost, quick to produce and relatively easy to modify when changes are needed.

Automatic Green Sand Casting for Dimensionally Complex Applications

Le Sueur Incorporated has (3) Automatic Casting Lines and (2) Cope and Drag Casting Lines for aluminum green sand molding. LSI specializes in dimensionally complex and pressure tight applications. Aluminum alloys poured include 319, 355, 356 & A356.

LSI also offers complete in-house core making, heat treating, machining, finishing and assembly services. We also provide design engineering assistance and offer prototyping services in the early design and manufacturing stages.

Our in-house Core Making consists of Isocure and Shell Core processes to deliver quality results.

Other technology utilized within our sand casting processes include:

  • Complete Metallurgical and NDT laboratories.
  • Metrology facilities to include CMM and 3D Laser scanning capability.
  • CAD Systems: Pro/ENGINEER & SOLIDWORKS
  • MAGMA casting simulation
  • X-Ray: Digital Radiography (DR), Computed Radiography (CR), and Conventional Film

Request a Quote for Sand Casting Today

Le Sueur Incorporated specializes in green sand casting and other aluminum casting methods to produce dimensionally complex, pressure tight aluminum castings. Our other services include plastic injection molding and complete in-house precision machining, finishing and assembly. Please contact us to learn more about our capabilities and discuss your sand casting project!