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  METAL CASTING - MOLDING  
 

Metal castings are used by most people everyday but very few have any idea of what they are or how they are made. To that end we have prepared the following to help better understand the casting process.

 
 
 
Molding - Nobake Sand Molding  
 

A mold is made by mixing sand (reclaimed at SWS) with a three part chemical binder system. This molding process is referred to as a Nobake or Airset System. Sand foundry molds are made in two parts, each representing one half of the part to be made. The top half is referred to as the 'Cope', the lower as the 'Drag'

The sand and binder is mixed in a dual trough, screw type, continuous mixer. As the mixed sand leaves the mixer it is discharged onto a pattern face mounted in a mold box.

After the mold box has been filled with sand, it is compacted to its maximum density to insure a strong mold for handing and pouring. After the mold is compacted, any excess sand is removed from the top of the mold box.

Once the sand has 'set-up', the pattern is removed from the sand in a Rollover/Draw machine. The mold is then 'Flow Coated' to improve casting surface finish. After the Flow Coating material has dried, cores are placed in the Drag portion of the mold. The mold is then closed by setting the Cope on the Drag. Once closed, the mold is moved to the pouring lines.

Making a Steel Casting Molding Schematic
   

Overview

Core Making

Melting

Molding

Cleaning

Terminology

 
   
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