NAME: MOLEBEDI SETLHAKO

ID NO:19000778
MODULE CODE: INME 313
MODULE NAME: Materials and Manufacturing Properties

Part One: Processing of the aluminium parts by Sand Casting process

Date of submission: 22-10-2021

BACKGROUND/LITERATURE REVIEW
It can also be referred to as sand molded casting, and it is a metal casting process done by using
sand as the mould material. Sand casting can also mean an object produced by using a sand
casting process, and that object can be made in various shapes. An estimated 60% of metals are
produced using the sand casting process. It entails a mixture of special sand, water and oil or
sometimes special bonding substances are used, in order to achieve strength and plasticity .A
variety of materials and equipment are used, and will be discussed under materials and
equipment.

MATERIALS AND EQUIPMENT LIST

 Sieve
 Parting Dust
 Cope and Drag (Casting Flask)
 Special Sand
 Molten Aluminium
 CRM 700 Tilting Crucible Furnace
 Steel Tongs
 Carving File
 Sprue
 Core(made from wood)
 Pouring Basin or Cup
 Oil and Water
 Wood Hammers
 Safety clothes(Goggles, Apron, Gloves and Overall )
 Medium sized Crucible

METHODOLOGY AND PROCEDURE

STEP 1
1. SAND PROCESSING
The sand was processed by being mixed with oil and water, in order to make a sand
mould.

2. PATTERN MAKING
A core made from wood was used to make the required pattern shape in the sand mould.
3. PLACING THE MOULD PATTERN IN SAND
The mould pattern was then mixed with some parting dust and placed inside the casting
flask .Sand was hammered on top of the mould pattern, making sure there was little air
spaces left. Some wood hammers were used to do that process.

4. MELTING AND OF ALUMINIUM

Aluminium blocks of required amount were then melted inside the CRM 700 Tilting
Crucible Furnace at the required temperature which was a temperature above 1000
degrees. Steel tongs were used to safely place the molten inside the furnace with safety
precautions observed.

5. REMOVING MOULD PATTERN

The mould pattern was carefully taken out of the sand mould using a gating system setup.

6. POURING MOLTEN METAL INTO MOULD CAVITY

After safely collecting molten aluminium into a Crucible, tongs were used to hold and
pour the molten into the mould cavity and it was left for some time to cool.

7. BREAKING OPEN THE MOULD

The mould was then broken in order to collect the newly made metal casting.

Figure showing solid aluminium inside mould cavity

References
https://en.wikipedia.org/wiki/Sand_casting
Degarmo, E.Paul; Black, J T.; Kohser, Ronald A. (2003), Materials and Processes in
Manufacturing (9th ed.), Wiley

https://www.custompartnet.com/wu/SandCasting