Pattern Making
Pattern-making step in which a replica of the object to be cast is made of suitable material. The pattern usually is oversized to allow for metal shrinkage during the cooling phase;
Mould Making
A sand mould is formed by packing sand into the mould around the pattern. The sand mould is divided into two halves, the top half is called the “Cope”, and the bottom is called the “Drag”. When the pattern is removed from the cavity, it forms remains for pouring the molten metal. Mould will have other features such as Sprue, runners, gate, pouring cup, riser etc., which will be discussed in detail later.
Clamping
The clamping step involves the two mould halves, Cope and Drag, securely clamped together, ready for pouring metal.
Pouring Molten Metal
Pouring molten metal is maintained at a set temperature. Molten metal is poured in quickly to avoid early solidification;
Cool and Solidify
Poured molten metal will begin to cool and solidify once inside the cavity. Most of the possible sand-casting defects are introduced at this solidification stage;
Casting
Once the cooling period elapses, the mould can be shaken out/broken off and casting;
