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This video provides a basic introduction to sandcasting.

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Sandcasting is a method of making metal parts by pouring molten metal into a mold made of sand.

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The first step is mold making.

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A pattern is used to make the sand mold.

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There are several types of patterns, like solid, split, or matching

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and the one used in this video is called a cope and drag pattern.

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The process begins by applying a release agent to the pattern.

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After this step, the pattern is placed in the mold box and filled with the sand.

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Once this process is completed for first half of the mold, the pattern is removed

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and the process is repeated for the second half of the mold.

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Once both halves of the molds are ready, then we can begin assembling the mold.

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If the part needs complex interior feature, then a core is needed.

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This example, a core is placed inside the mold to form a hole.

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Two halves are clamped together in the next step.

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The next step is pouring.

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The molten metal is kept at a controlled temperature in the furnace.

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Once the mold is securely clamped, the metal is quickly ladled from the furnace and poured into the mold.

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The pins used to secure the core, called chaplets, are typically made from the same metal,

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so that it eventually melts and is absorbed by the part.

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The molten metal cools and solidifies inside the mold.

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The next step is removal of the part from mold and removal of core.

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The final trimming step removes all the excess material, such as gates and risers.

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There are several key features of sand casting.

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Sand casting is also compatible with a wide variety of metals, including high temperature metals

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that are unsuitable for other metal processes like die casting.

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Compared to other processes, sand casting is not volume constrained due to its gravity-based nature and slow cooling,

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so it can produce very large parts like ship propellers or engine blocks.

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However, sand casting leaves a rough surface finish,

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and parts often need machining or post-processing after casting, depending on subsequent operations.

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This process is also slower than a permanent mold process because molds need to be remade each time.

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Common products of sand casting include marine parts, ship propellers,

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our manhole covers, engine blocks, automotive parts, cookware, artwork.

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Sand casting uses a pattern to create sand mold.

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Pattern can be created using 3D printing or machining.

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There are many different types of patterns.

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Some patterns use two separate parts representing top and bottom parts of the mold.

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In some patterns, two parts are held together using a plate.

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Common part materials used in sand casting include alloy steel, carbon steel, cast iron, stainless steel, aluminum, copper, magnesium, nickel, lead, tin, titanium, zinc.

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The cost can vary depending upon the part.

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Material cost depends on the type of metal.

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Aluminum is cheaper than copper alloys.

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Tooling and mold preparation cost depends on pattern costs.

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Patterns made from wood cost between $500 to $2,000.

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Metal patterns cost between $3,000, $10,000.

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Mold making, pouring, and finishing requires work by skilled labor.

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Skilled labor costs vary by region $20, $50 slash hour.

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Energy for melting metals adds to expense.

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Finishing and quality control steps such as machining, heat treatment, inspections, and certifications also add to the costs.

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Complexity and size of casting also affects cost.

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More intricate or larger castings require more materials and labor.

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Set up costs, lead time, rush fees, shipping, and operational overheads also increase the cost.

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Thank you for watching.

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To learn more about the different manufacturing processes, please check out the Custom Partner website.

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To learn more about the different manufacturing processes, please check out the CustomPartNet website.