Cast Iron Manufacturing Processes & Capabilities

Green Sand Molding 

Uses a mixture of sand, water and a clay or binder.

Green Sand Molds are the least expensive and most widely used in the metal casting industry.

Skin Dried Molding

Starts much like a green sand mold but with additional binding materials.

The cavity surface is dried with a torch or other heating equipment to increase mold strength.

This improves the dimensional accuracy and surface finish but increases the chance of collapse.

Dry Skin Casting takes more time, decreasing production rates.

Dry Sand Molding

In a dry sand mold the sand can be green sand modified with additional binders or often sand mixed only with organic binders.

The mold is then strengthened by baking in an oven.

This type of mold has high dimensional accuracy but results in lower production rates.

No Bake Molding

The sand in a no bake mold is mixed with liquid resin.

The mold, due to the addition of the resin, will harden at room temperature.

Produces excellent surface finishes and can be used for very large castings.

The Cold Setting Process refers to any of several systems for binding molds or cores which relies on the use of catalysts rather than heat to harden.

The cold box process usually refers to a rapid core making process.

Hardening is achieved by chemical reaction rather than conventional baking. 

A resin is added to the sand which reacts chemically when exposed to an accelerator, usually an organic gas, and hardens very quickly. 

This reaction occurs at room temperature.