The applications of die casting and sand casting differ from on

  • There are many different types of casting used in the industry today, and each type is designed to achieve a specific objective. In the sand casting process, molten metal is poured directly into a sand mold from a ladle, with no need for high pressure. In order to create a mold, a pattern made of wood or plastic (typically referred to as a matchplate) is placed inside an enclosure and allowed to dry for several days. After that, sand is used to fill in the gaps around the matchplate and inside the enclosure. After the sand has been added and compacted tightly, the matchplate is removed and the remaining cavity is filled with molten metal until the matchplate is removed. As soon as the metal solidifies, the mold is opened and the sand is shaken off the hot casting, which results in the production of a finished product. By now, the gating material has been removed and the casting has been completely finished.

    It will then be necessary to prepare the mold for the next "shot," which will require some downtime while sand is placed around the matchplate and inside the enclosure, as in a sand casting. In order to minimize the amount of downtime that occurs (up to 5 minutes per casting), sand casting is best suited for parts that are produced in smaller quantities. A disadvantage of this process is that the materials used in it typically produce less detail in the final products, requiring more secondary operations than traditional die casting. The molds for sand casting can be seen in the image above.

    What is the difference between die casting and sand casting?

    The applications of die casting and sand casting differ from one another, aside from the most significant difference between the two processes – the materials used to form the molds – and are discussed below. Castings for medical device manufacturers, for example, will need to be precise and have complex shapes in order to be effective. Because of their requirements, die casting is most likely the most appropriate method for their project.

    A furniture manufacturer, on the other hand, may find that sand casting is more cost-effective for their manufacturing needs. Sand-cast parts frequently have a thicker wall than die-cast parts, allowing for larger sizes of the final product to be produced accurately while requiring less precision. Textured imprints are also frequently found on the products. With a granular finish or imperfections that suggest antique-like qualities, these imprints can enhance the aesthetics of a piece of furniture or decor item, making it more appealing to the eye. In contrast, a smaller-shaped product with greater complexity and a requirement for precise application would suffer as a result of this limitation.

    The processes for creating a die-casted product and a sand-cast product are fundamentally different, but both have legitimate uses in commercial manufacturing. Die casting will save money in the long run for companies that have a long enough lead time and are willing to bear the higher cost of having their molds made out of steel in the short term. Reusing the dies not only ensures accuracy, but it also results in lower production costs over the course of time. For this reason, all of the items that require casting can be set up and produced in a single session, and then the process can be repeated as needed. Die casting can also produce features that are not possible with sand casting, resulting in a reduction in secondary costs when compared to sand casting.