Making a foundry core is hardly rocket science. All it takes is a bit of sand, molten metal and maybe a chemical or two plus a commitment to safe practice and a bit of know-how. The process is breathtaking in its simplicity. Back in the Bronze Age, when there were no production targets or deadlines, early blacksmiths could melt down and re-pour their mistakes until they were happy with the final result.
If you have a small business casting metal, you don't have time for do-overs. If your foundry guy moves on to greener pastures, it can take a while to find someone with the same skill set and knowledge base. It's time to think about outsourcing your cores.
Approximately 70% of all cast metal objects are made by the sand casting process. There are a number of different approaches to sandcasting cores. These include air set no-bake, shell, isocure and the warm box method. Each one has its own unique advantages.
When the desired outcome is a thin-walled core, it has to be strong enough to hold up to the molten metal without breaking down or eroding. For this, the warm box process is employed. Furan, a simple aromatic hydrocarbon, is mixed with the sand as a fixative. The catalyst in this process is heat. However, the boiling point of furan is uncomfortably close to room temperature; this makes it both flammable and volatile. A very good reason to outsource this work to a company that is used to handling it. Once cast, the cores are heated until the outside of the core is hard. Inside, cooling continues to cool.
The no-bake air set method is ideal when you have a detailed design and want a small to medium volume. A mixture of plastic and sand is tightly packed around a "positive." This method can produce a casing up to 225 pounds in weight. The air set method is adaptable for a variety of materials, including plastic, non-ferrous metals, fiberglass and styrofoam.
In the isocure core-making process, a polyurethane resin is added to the sand. A catalyst, sometimes an amine gas, is injected into the box and superheated air is blown through. This method is fast and economical for large cores.
When the desired outcome is for a fine, detailed finish, the shell process is optimal. The casting box is headed and then filled with pre-treated sand. The outside is then heated to generate a thin, hard shell. Another advantage of using this method that the uncured sand on the inner core can be poured out and reused.
Sand casting for foundry core production has been around since around 3,500 B. C.; that's way before even Moses walked the Earth. The reason it has stood the test of time is because of its reliability and versatility. Back in Moses' time, things were different and metal smiths had no problem melting down their mistakes. Over the years, the process has evolved in many different directions. It has always been a dangerous process. For many reasons, businesses today often outsource their foundry work.
If you have a small business casting metal, you don't have time for do-overs. If your foundry guy moves on to greener pastures, it can take a while to find someone with the same skill set and knowledge base. It's time to think about outsourcing your cores.
Approximately 70% of all cast metal objects are made by the sand casting process. There are a number of different approaches to sandcasting cores. These include air set no-bake, shell, isocure and the warm box method. Each one has its own unique advantages.
When the desired outcome is a thin-walled core, it has to be strong enough to hold up to the molten metal without breaking down or eroding. For this, the warm box process is employed. Furan, a simple aromatic hydrocarbon, is mixed with the sand as a fixative. The catalyst in this process is heat. However, the boiling point of furan is uncomfortably close to room temperature; this makes it both flammable and volatile. A very good reason to outsource this work to a company that is used to handling it. Once cast, the cores are heated until the outside of the core is hard. Inside, cooling continues to cool.
The no-bake air set method is ideal when you have a detailed design and want a small to medium volume. A mixture of plastic and sand is tightly packed around a "positive." This method can produce a casing up to 225 pounds in weight. The air set method is adaptable for a variety of materials, including plastic, non-ferrous metals, fiberglass and styrofoam.
In the isocure core-making process, a polyurethane resin is added to the sand. A catalyst, sometimes an amine gas, is injected into the box and superheated air is blown through. This method is fast and economical for large cores.
When the desired outcome is for a fine, detailed finish, the shell process is optimal. The casting box is headed and then filled with pre-treated sand. The outside is then heated to generate a thin, hard shell. Another advantage of using this method that the uncured sand on the inner core can be poured out and reused.
Sand casting for foundry core production has been around since around 3,500 B. C.; that's way before even Moses walked the Earth. The reason it has stood the test of time is because of its reliability and versatility. Back in Moses' time, things were different and metal smiths had no problem melting down their mistakes. Over the years, the process has evolved in many different directions. It has always been a dangerous process. For many reasons, businesses today often outsource their foundry work.
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