Sand Metal Casting is the most ancient form of metal casting and has been around since at least Ancient Egypt. Many metal casters prefer using sand casting over many of the other forms of processes because it’s cheap and the sand used is readily available.
Many experienced metal casters will continue to use sand casting even though their abilities and resources allow them to use the other metal casting methods like Lost Wax Casting or Investment Casting. Sand casting involves less material and less effort than the other casting methods. Sand casting is a great way for new casters to get into the trade.
In sand casting, the metal caster will create a mold by placing an original in the flask which is filled with sand. The original will be a pattern of what you want to cast. By ramming or vibrating the sand, the caster creates a mold of the original. The casting sand used needs to be able to retain the shape of the mold. Your water and sand mixture is one of the most important parts of making your mold. Too much water can ruin the mold and possibly destroy it while too little water will create a poor casting. One of the reasons that Green Sand is liked among casters is that its easier to retain the shape of your mold with Green Sand. If you take Bentonite Clay, Sand, and Water you will probably get some form of Green Sand.
After the sand is packed, the pattern or original is removed carefully. Molten metal is poured into the mold and allowed to cool. The metal caster will then break the mold and dig out the casting.
While sand Metal Casting has its benefits the use of green sand can greatly increase the likelihood of a successful casting. Green sand is not really green the color refers to the damp nature of the sand. Green sand is created by adding water and bentonite to the sand. One of the benefits of using bentonite in green sand is that it makes the sand more permeable which allows more gas to escape.
Metal casters can get the bentonite from a variety of sources like home improvement stores and even from household resources. Many have milled the type of cat litter that clumps since one of the ingredients is bentonite. Remember to work in a well ventilated room or to wear proper face gear when working with bentonite since it will irritate the lungs.
A lot of Casters will start with a Green Sand Recipie but then start to make their own tweaks with experimentation. What you are looking for when mixing the sand, water, and bentonite is a texture that is not wet but damp and will retain its shape when molded.
The type of sand you use to make green sand depends on you and the availability of the sand. Many will use sand that they found out in the wilds of nature and some will buy bags of sand like playground sand. As you cast with green sand you will find out which works best with what metals.
Green sand is growing in popularity as more casters are recognizing the properties of this method. If you have traditionally used regular sand casting, green sand casting will prove to be easier to work with and will produce better casts.
The best part about green sand Metal Casting is that is does not cost a lot of green.
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