Pre-coated Resin Sand Castings for Automotives

- Sand Selection: Silica sand with high quality is largely preferred as raw material. The grains in it are in a desirable distribution between 50 - 140 mesh in a way that it can be satisfactory packable as also fluid in case of moulding.

- Resin Coating: Thermosetting resin, i. e., phenolic resin is used in coating the sand. The heat resistance, bonding strength, as also as character of curing, are select with care in a suitable resin. The application amount is usually 1 - 3% in terms of weight in relation to the sand, varying with a requirement in a casting.

- Mixing: The resin is mixed with the sand in a high-speed mixer. A catalyst can be added in mixing in order to produce initiation of a curing reaction in the resin. The mixing is timed with great care in order to achieve a homogenous coating on grains of sand.

- Curing: Pre-coated sand is cured at appropriate heat after mixing, which is generally 150 - 250°C. The stiffening is achieved in the resin coating that makes the sand have its traditional shape - holding quality.

- Pattern making: The pattern in wood, plastic, or metal is created according to the casted vehicle design. The pattern is established in order to form cavities in a mould that is cast in sand.

- Mold making: Pre-coated resinsand is packed into pattern in boxes. The sand is pressed tightly in order to have a good density as well as eliminate gaps. A series of moulds can be stacked in order to produce a complete mould assembly in case of complex automotive castings.

- Melting: The material alloy, i.e., steel, aluminum, or iron, is melted in a furnace. Melting is carefully monitored in order to control material melted as well as heat contents.

- Pouring: The metal is cast into pre-prepared moulds. The rate of pouring as well as pouring temperature are essential not to have defects in terms of porosity, shrinkage, as well as cold shuts.

- Shakeout: The castings are shaken out from moulds made of sand that are crushed once castings are hardened. The process is referred as shakeout.

- Finishing: The castings are subjected to a series of finishing treatments, i.e., trimming, grinding, as well as machining, in order to attain specified dimensional accuracy as well as surface finishes. The castings are also heat treated in order to enhance castings' mechanical properties.

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