Sand Casting

Sand casting production line
Sand casting production line
Automatic Sand casting production line
Automatic Sand casting production line
Assemble sand mold
Assemble sand mold

Sand Casting where quality is guaranteed

Omnidex Mining is an expert in Sand Casting with over 16 years of experience in the field, and we have just celebrated 10 years of ISO 9001 certification. Our total commitment to quality is what makes us stand out from others.

Our Expertise in Sand Casting

British owned and managed, Omnidex Mining makes high quality Sand Casting parts at competitive price by liaising with specialized foundries in China and Vietnam. We have been working with these highly experienced, specialist foundries for many years and we have a thorough understanding of their capacity and performance. Here are the pros and cons of Sand Casting:

Pros

  • The process can produce very large parts. Our Sand Castings range from 1 kg (2.2 lbs) all the way up to 15MT
  • Parts can be made from a variety of materials, including special steels (such as high manganese, high chrome and high nickel steel), grey iron or ductile iron, as well as non-ferrous metals
  • Tooling is relatively inexpensive for this process
  • The process can handle a wide range of shapes and designs

Cons

  • This process usually produce more waste, in the form of sand, feeds, uprisers and ballasts. (This can be reduced if the waste is reclaimed and treated properly)
  • The process may also suffer from dimensional inaccuracy and other defects caused by shrinkage, porosity and pouring errors. (This can be prevented with proper engineering. Read more on how we prevent Sand Casting defects below)

Guaranteed quality with our Sand Castings

Omnidex Mining excels in the quality of sand castings. We often work with companies to produce castings for equipment valued at many millions of dollars, and any error or fault can be very costly.

We are also aware of the inconsistent quality in some of the products on the market. Some suppliers in the Sand Casting sector can struggle with quality control, especially when the pressure is on and a heavy daily output is required. Here are some of the more common Sand Casting issues:

  • Hot Tearing: Caused by a non-uniform cooling rate.
  • Porosity: Caused by a non-uniform cooling rate, a melt temperature too high, or the use of sand with low permeability.
  • Surface Projections: Caused by shifting of the mold halves, erosion of the mold interior or a crack on the mold.
  • Unfilled Section: Caused by a pouring temperature that is too low or not enough molten metal is used.
The Shell is filled with molten metal
The Shell is filled with molten metal
Green Sand Recycle System
Grinding
That is why we offer a guarantee on the quality of our castings – no porosity, no inclusions, total dimensional accuracy and all materials certified. Should our customer not satisfied with our work, all payments will be refunded, no questions asked. Learn more about our Omnidex Mining Guarantee here.

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Quality Sand Casting is what we do

Regardless of what some traditional foundries might tell you, there is no mystery or magic when it comes to Sand Casting – Our casting process follows a series of tried and tested procedures to achieve its full potential. These include pattern making, mold making, pouring, cooling and shakeout, reclamation, cleaning, fettling and finishing. 

Omnidex Sand Casting Process Video

Our goals are simple: zero porosity, zero inclusions and impeccable quality. Issues such as shrinking defects and porosity can be prevented if Sand Casting is done in the right way. Here is how we ensure the quality of our products:

  • Every casting starts with the pattern (made in wood or aluminium). Accuracy is essential at this stage, which is why all Omnidex patterns are CNC machined with specialized equipment designed for large castings projects.

Sand Casting Parts

Sand Casting Pattern

  • Our engineers will ensure all shrinkage allowances, draft angles and removable cores are accurately calculated –the shape and size of the parts, location of feeds, uprisers, chill blocks and every factor are well thought out to produce the perfect pattern.

Resin Sand Core

Automatic Sand Mold Building Machine

  • Next, our Sand Casting specialists will calculate how the molten metal fills the sand mold. They will take into account the metal flow in the sand mold, material cooling and many other factors to prevent issues such as uneven shrinkage or surface distortion.
Spectrograph machine

Spectrograph Machine

Casting slicing

Casting Slicing

  • After all the calculations, every new pattern goes through a thorough simulation test. This allows our engineers to estimate the likelihood of porosity so they can move, increase or decrease the feeds and uprisers or add chill blocks as required. We often work with complex and expensive parts, so we insist to carry out several simulations before making the final decision.
Porosity simulation

Porosity Stimulation

Pre-production simulations

Pre-production simulations

  • Ferrous castings are pre-treated with zinc phosphate which provides a high level of corrosion protection, and finished with anti-rust coatings, zinc plating, powder coatings or spray painting.
Anti-rust coatings

Anti-rust Coatings

Powder Coating

Powder Coating

Choose the best process for your project

Sand casting can be used to make a diverse range of products, including very large casting pieces. Materials are relatively inexpensive and can resist deformation in tough conditions.

Sand Casting Parts
Sand Casting Part
Sand Casting Part
Pump Casting Part
Crusher Jaw Plate
Sand Casting part
Sand Casting part

Sand Casting can be used to make a diverse range of products, including very large casting pieces. Materials are relatively inexpensive and can resist deformation in tough conditions.

Just like any other processes, Sand Casting does have its limitations (such as a higher level of waste), but in the hands of experts and specialists, it is by far the best process to use when producing large, complex components with extremely close tolerances.

If you are looking for a Sand Casting specialist to help you with your next project, don’t hesitate to contact us. You can also learn more about other casting processes on this website.

Get in touch with Omnidex Mining if you need more information or a quote.

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Phone no.:
Asia Pacific, South America, Africa and the rest of the world: +86 20 8388 7080
UK: +44 (0) 7769 633868

Email

mining@omnidexgroup.com

Omnidex Mining Brochure

Omnidex Mining Industrial Manufaturing Engineering Services_Mining Equipment Brochure_2022

If you are looking for Industrial Mining Equipment & Machinery services, our brochure is a great way to discover what Omnidex has to offer. You can download HERE to learn more.

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