Basics
What is sand casting?
A manufacturing process in which molten metal is poured into a sand mold cavity.
What is a pattern?
A replica of the final product used to create the mold cavity.
What is the most common molding material used in sand casting?
Silica Sand
What defect appears as gas cavities in a casting?
Blowholes
Which automotive component is commonly manufactured by sand casting?
Engine Block
What is the primary purpose of a mold in sand casting?
To provide the shape of the final casting.
What is the function of a core?
To produce internal cavities or holes in castings.
Which material acts as a binder in green sand molds?
Clay (Bentonite)
What defect occurs when molten metal fails to completely fill the mold cavity?
Misrun
Which heavy engineering component is commonly produced by sand casting?
Pump housing
Which state of metal is poured into the mold?
Molten (liquid) metal.
What is the upper half of a mold called?
Cope
What is green sand?
A moist mixture of sand, clay, and water used for mold making.
What defect is caused by contraction during solidification?
Shrinkage cavity (Shrinkage porosity)
Why is sand casting suitable for prototype production?
Low tooling cost
What is removed after solidification to obtain the casting?
The sand mold.
What is the lower half of a mold called?
Drag
Which ferrous metal is most commonly produced by sand casting?
Cast iron
What defect appears as cracks formed at high temperatures during solidification?
Hot tears
Which industry extensively uses sand-cast components?
Automotive industry
Why is sand casting widely used in manufacturing?
It is economical and suitable for complex and large components.
Which channel carries molten metal from the pouring basin to the mold cavity?
Runner
What property allows molding sand to withstand molten metal temperatures?
Refractoriness
What is the name of excess metal formed at the mold joint?
Flash
Name one advantage of sand casting for large components.
It can produce large and complex shapes economically.