Sand Casting
The benefits of sand casting are numerous. There are minimal restrictions on the shape, size, and material. The process is extremely efficient by using dry sand, green sand, or chemically bonded sand. Sand casting is a better option over die casting because it allows for low or high-volume production.
Sand Casting Products
Impro’s experience in creating high-end sand castings from high-grade materials and consisting of complex geometries is beyond comparison. In our high-tech facilities, we offer both machine and manual molding operations in our resin sand casting processes. We produce parts in low-to-high volumes and pour castings ranging from 0.5 kgs to 20 tons. Our green sand castings range from 0.5 kgs to 30 kgs.
Impro’s Sand Casting Capabilities
Impro’s inspection capabilities are top of the line. Spectrographic and manual quantitative analysis; metallographic analysis; Brinell, Rockwell and Vickers hardness inspection; mechanical property analysis, low and normal temperature impact testing; cleanliness inspection; and UT, MT and RT inspection are all conducted on site at our facilities.
Our inspection equipment is top-grade. Our Speck spectrometer checks 28 chemical elements. Our Zeiss metallurgical microscope produces high-resolution images 1,000 times magnified, and our Zeiss cleanliness meter determines particle size and quantity to ensure materials meet or exceed the international standard. We use GE ultrasonic detectors to discover flaws, and have X-ray machines and accelerators that can scan castings with 200 mm maximum wall thickness.
What We Offer
Our services are varied and extensive. We offer material advisory service and development, as well as advice from our technical experts on design and casting. We do 3-D CAD drawings, simulations, and component machining. We also offer cavity fill, solidification, tension and distortion services. We provide assembly, testing and qualification, heat treatment, and surface treatment. From start to finish, we have you covered every step of the way.
Learn More
Impro is dedicated to the quality of our work, and our commitment to excellence ensures the highest customer satisfaction. As a global leader in high-precision, high-complexity, and mission-critical casting and machined components, we strive to meet and exceed the needs of our customers. To learn more about our sand casting services and capabilities or to discuss options for your next project, reach out to the team today.
SAND CASTING 3D ANIMATION
high-end sand castings of complex geometries and high-grade materials
Primary Equipment for Sand Casting
Full-Service Sand Casting
Impro offers one-stop solutions for all your sand casting needs. We provide a full suite of state-of-the-art process technology and equipment throughout our multiple facilities.
Listed below are Impro’s sand casting equipment and process capabilities.
Core Making
- Hot-box core making is used for medium- and high-volume production
- Machines: KC800, KC600, and KC400
- Sand injection pressure: 0.4–0.6 Mpa
- Max. sand core weight: 40 kg
- Cold-box core making is used for medium- and high-volume production
- Machines: 80L Cold-Box Core Making Machine and 450L Cold-Box Core Making Machine
- Max. sand injection pressure: 5 kg
- Max. sand core weight: 500 kg
- Max. size: 1,600 × 1,600 mm
Molding
- Resin-sand process
- Plant 6 owns three resin-sand production lines as well as manual molding machines
- Applicable for medium- and large-sized or small-volume, small-sized parts
- IMF Automatic Molding Line: for large parts or small-volume production
- Automatic molding system (pattern withdrawing, coating and drying system
- 10 molds/hour
- Flask size: 4,200 × 3,200 × 1,000/1,000 mm
- IMF Automatic Molding Line: for medium-sized parts
- Product size: 1,200 × 1,000 × 800 mm
- Current capacity: four molds/hour
- Product weight: 50–1,000 kg
- Product type: ductile iron or gray iron
- IMF Automatic Molding Line: for small parts
- Product size: 1,100 × 800 × 200 mm
- Current capacity: 10 molds/hour
- Product weight: 1–50 kg
- Product type: ductile iron or gray iron
Green sand process
- Plant 7 owns two FBO Automatic Production lines and a Z149 production line
- Produces of medium- and small-sized parts 100 kg
- Processes volumes greater than 1,000 pieces/year
- FBO Automatic Molding Line
- Product size: 610 × 510 × 200 mm
- Current capacity: 60 molds/hour
- Product weight: 0.5–50 kg
- Product type: ductile iron or gray iron
- Capacity utilization: 50%
- Z149 Molding Line
- Product size: 900 × 700 × 300 mm
- Current capacity: 60 molds/hour
- Product weight: 1–100 kg
- Product type: ductile iron or gray iron
Pouring
- Melting furnace volume: 1–6 tons
- Normal ductile iron: GGG35~80
- Normal gray iron: GG15~35
- Heat-resistant ductile iron: SIMO D-5S
- High-strength and -toughness ductile iron: ADI
- Compacted graphite cast iron: 400 (pearlite) and 350 (ferrite)
Heat Treatment
- Relief annealing
- Max. temperature: 700°C
- Size: 7,200 × 2,500 × 1,700 mm
- Max. load: 3,5000 kg
Summary
Impro offers a full range of sand casting solutions. If you would like to know more about our technology and sand casting process capabilities, please contact us today.
Sand Casting Material Capabilities
Ductile Iron
EN-GJS-350-22/LT
EN-GJS-400-18/LT
EN-GJS-400-15
EN-GJS-450-10EN-GJS-500-7
EN-GJS-550-5
EN-GJS-600-3
N-GJS-700-2
EN-GJS-800-2
EN-GJS-SiMO40-6
EN-GJS-XSiMo5.10
S-500-10
Compacted Graphite Iron
GJV450
High SiMo-Ductile Iron
STD-02-0811*
Grey Iron
EN-GJL-250
EN-GJL-300
EN-GJL-350
Austempered Ductile Iron
High Nickel Ductile Iron
Sand Casting Inspection Capabilities
Impro has a full range of inspection capabilities in house, which include:
- Spectrographic and manual quantitative analysis
- Metallographic analysis
- Brinell, Rockwell and Vickers hardness inspection
- Mechanical property analysis
- Low and normal temperature impact testing
- Cleanliness inspection
- UT, MT and RT inspection
Sand Casting Processes Capabilities
| Process | Weight Range | Suitability | Process Parameter |
|---|---|---|---|
| IMF Automatic Resin Sand Molding Line |
20~220 KG | Size range: 100-800 mm, wall thickness above 5 mm |
Flask size: 1200x800x500/500 mm; 9 molds/hour |
| IMF Automatic Resin Sand Molding Line |
50~300 KG | Suitable for medium and large sized ductile iron, grey iron and CGI products | Flask size: 1600×1200×600/600 mm; 4 molds per hour |
| IMF Automatic Resin Sand Molding Line |
1~8 T | Suitable application: V-type and Line Engine cylinder block |
Flask size: 4200×3200×1000/1000 mm 5 molds per hour |
| Sinto FBO Automatic Green Sand Molding Line | 0.5~20 KG | Suitable for medium-volume and small and medium sized castings | Flask size: 610×508×250/250 mm 80 molds per hour |
| IZ149 Molding Line | 1~100 KG | Suitable for various castings from low to high volume | Flask size: 900×700×300/300 mm 60 molds per hour |
| Resin Sand Manual Molding, Pit Pouring |
0.5～20 T | Suitable for low-volume castings and prototypes | – 150 molds per hour for the small parts – 45 molds per hour for the large |
Detailed product description for resin sand castings:
- Cylinder Block: All types of inline and “V” type up to 3,200 kg per piece, raw or machined.
- Cylinder Heads: From 40 kg per piece to 300 kg per piece, multi-cored, raw or machined.
- Hydraulic valve bodies
- Gear Box parts
- Other complex cored castings up to x tons
- Machine molding, manual molding
Medium to High Volume Green Sand Casting
Our machine molded castings department manufactures castings with a weight from 0.5 kg to 20 kg
Detailed product description for green sand castings:
Hydraulic valve bodies
Gear Box parts
Planet carrier
Steering knuckles
List other primary products
Other complex cored castings up to 30kg
Machine molding, manual molding
Our services include:
- Material advisory service and development
- Technical advice on design and casting
- 3-D CAD drawings
- Simulations
- Cavity fill, solidification, tension and distortion
- Component machining
- Assembly
- Testing and qualification
Sand Casting Product Description
Cylinder Head
sand-casting
Material: Compacted Graphite Iron (CGI)
Application: High-horsepower Engine
Manifold
sand-casting
Material: Si-Mo Ductile Iron
Application: Construction Equipment and High-horsepower Engine
Combustor
sand-casting
Material: High Si-Mo ductile iron
Application: Construction Equipment and High-horsepower Engine
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