Green Sand Molding 201

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Learning Outcomes

  • Summarize the typical green sand systems used for various alloys.
  • Identify applications requiring specialty sands.
  • Describe common sand additives used in green sand metalcasting facilities.
  • Identify the equipment and processes used to handle and reclaim sand.
  • Examine green sand process variables and how to make adjustments.
  • Explain the various quality control tests used in green sand foundries.
  • Use quality test data to evaluate green sand for corrective action.
  • Recognize common quality control problems.
  • Describe the important safety measures and operating practices to use in green sand foundries.

Course Introduction: 

The first day includes a review of important raw material requirements for green sand systems, an introduction to applications requiring specialty sands, and the types of sand additives and their effects on green sand. You will explore key concepts for sand equipment, sand handling and storage, sand reclamation and re-use, and have access to important safety procedures used to avoid injury.

The day culminates in a look at green sand process variables and methods to make adjustments to these variables to ensure a quality mold is made. The second day will focus on green sand quality control tests for ferrous and nonferrous alloys, the types, purpose, frequency, and typical result ranges for each. You will discuss typical problem areas seen in green sand metalcasting facilities and how test results can identify areas for correction. The day will finish with an introduction to statistical process control for sand systems.

Benefits to Taking the Course

Participants will obtain essential knowledge for green sand molding as it is used in established metalcasting facilities. The course provides a basic foundation of the green sand mold making process, and stages the process of recognizing green sand process variables and how to make minor adjustments when variables need correction. This course addresses the types of tests used for controlling green sand mold quality, and how those test results begin to shape changes in the process.

Module 1: Introduction

Module 2: Green Sand Molding Issues

  • Green Sand Molding Scenarios

Module 3: Sand, Clay, and Mixes

  • Sand and Clay
  • Typical Green Sand Mixes

Module 4:  Components of Green Sand Systems

  • Facing and Specialty Sands
  • Sand Additives

Module 5: Sand Handling and Mixing

  • Sand Handling and Mixing Equipment
  • Sand Storage
  • Reclamation and Reuse

Module 6: Green Sand Quality Control Testing

  • Quality Assurance Testing
  • Quality Assurance Problem Areas

Module 7: Green Sand Quality Control

  • Green Sand Variables and Process Relationships
  • Sand System SPC Overview
  • Developing a Control Strategy

Module 8: Conclusion


What our students have been saying.....

"It was a world-class group of experience and knowledge."
"I’d like to take more classes on this."
"I liked the group interaction."
"Great job and thank you for passing on and sharing your knowledge."
"It was good to break into groups by alloy. It was more beneficial to work through similar problems with similar alloys."