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7. Cracking the mold

SAND CASTING

Jesus Daniel Gomez EliasNicolas Servin LuqueMnica Pamela Veyna Arredondo

Basics of Sand Casting #1

Sand casting is a process that uses a mold made from either metal or wood, to create a negative impression in a special sand that will be the mold for the molten metal. This mold is then filled with a molten metal that is left to cool and solidify.

Tools Needed:

Silica Sand

Mold of object

Some type oven to melt the metal you will be using

Ladle to pour molten metal

Block of solid metal to melt

Hammer or some other object to crack the sand mold after metal solidifies

Preparation for sand casting #2Decide the object. Once you have decided on the object you want to make you will need to figure out how you can cast the object and still be able to remove the sand mold from the form. It is also important to remember that you will need to leave a hole in the sand cast to pour the molten metal through when it is assembled.

While removing one of the molds that was used in making the mug it fell apart because it was not completely solidified and is shown below.

Ensure the sand is hard before attempting to remove the mold

Obtain assistance if needed to remove the sand mold

Tap the bottom of the mold to jar the sand lose from the edges

Remove the sand mold and place it in an area where it will not get knocked or dropped

Repeat for all parts of the sand mold that are needed

Filling the form with sand #3

Once you have your object that you will be casting made into forms it is time to pour sand over the top to make your negative impression into the sand.

It is important that all the sand gets packed in tightly to prevent any gaps in the mold that will cause the molten metal to flow someplace it is not supposed to flow

Ensure mold is clean and free of any dirtPour sand into mold ensuring that it is packed tightly around all corners and edgesLet the sand solidify for roughly 40 minutes before removing the sand mold from the form

Step 4.Removing the sand mold

Removing the sand mold is probably the most delicate part of this process. While the sand is hard enough to hold together it is not strong enough to withstand any sort of drop or sudden impact.

Step 5.Assembling the sand mold

When assembling the sand mold ensure that the cavities that will be filled with metal are free of any debris or lose sand that may be present.

1) Clean all debris from sand mold cavities2) Properly align cavities to ensure proper metal solidification

Step6. Pouring the molten metal

Put on the proper protective equipment

Clear the area of any hazards that are present

Carefully fill the ladle with metal and transport over to your sand mold

Pour metal into mold slowly ensuring not spill any metal

This is the most dangerous part of sand casting, and it is highly recommended that you read through the safety precautions of step 9.

7. Cracking the mold

As with any project there is always some destruction involved and this is it for sand casting, grab a hammer or metal rod and give the mold a good swing to crack the sand shell away from the metal object. Have fun with this and enjoy some destruction!

8. Quench your object in water

It is obvious that this newly formed object is going to be very hot, after all it was molten metal just a short time ago. It is best to use a pliers if the object is small enough and allows it, or you can always dump water over the top of the object to cool it down and prevent any burns from touching the hot surface.

9. Safety Concerns and Precautions

Safety is extremely important when working with molten metal because of the temperature at which the metal is at. For this reason it is important that you have a clear work area and make a plan for how you are going to move the molten metal prior to making any movements with metal in hand. Listed below are some primary safety concerns and as always this list is incomplete but with some common sense and by following these rules sand casting can be a fun and exciting time.