Sand Casting

Flexible Solutions Using Proven Processes. 

Our sand casting process can successfully cast small to medium serial items in a wide variaty of alloys. We individual castings in our hand-moulding shop and use our boxless, cold-resin block moulding plant or automatic core block moulding machine for large production runs.

3D Printing System – Innovative Possibilities. 

Our innovative 3D printing system allows for new possibilities: Based on CAD data we are able to produce sand moulds and cores for prototypes, single spare parts and complex serial parts. Not only are the development times reduced, pattern costs are eliminated and our customers benefit from increased engineering opportunities. 

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Sand Casting Products

VALVE HOUSING

Characteristics

Various types and sizes, Unit weight: 10 to 50 kg
Material: GX2CrNiMoN 25-6-3 (1.4468) nitrogen alloyed duplex steel
Batch size: 5 to 15 pieces
supplied with inspection certificate according to EN 10204-3.1

Target Setting

High surface quality of the flow-optimised interior. Post-machining is virtually impossible due to the specialised geometry of the outlet opening.

Solution

The valve housing depicted can handle an operating pressure of up to 100 bar and regulates the flow of aggressive media. Unlike moulding sand, this duplex steel with an extremely low carbon content does not react with the ceramic core: Any possible surface degeneration of the casting surface and consequent influence of corrosion is thus prevented.

COMPENSATING RING

Characteristics

20 types and sizes
Material: EN-GJS-XSiMo4.05 and wear-resistant alloyed cast iron
Batch size: 2 to 24 pieces
supplied machined, ready to be installed

Target Setting

Very fast production time. Reduces of machining costs.

Solution

The liner blanks are sand-moulded on the cold-setting resin plant; Wolfensberger can offer special silicon-molybdenum alloy nodular iron or wear-resistant cast iron because of the broad product range and corresponding experience. We found a manufacturing method that makes the manufacture of various seating rings from one basic blank possible, thus reducing pattern costs and turnaround times.

HOUSING / CASING

Produktdaten

Unit weight: 15 kg
Material: GX4CrNi 13-4 (1.4317)
Batch size: 20 to 100 pieces
supplied machined, ready to be installed

Target Setting

High surface quality, machining ready for installation, possibility of creating assembly variants quickly.

Solution

The aim in pattern design was for profile adaptations to be made simply and quickly using replacements parts without incurring significant costs. Additional webs, which could only be fitted in at the expense of quality and at higher prices by using complicated cores as a pure casting solution, are inserted using weld-in parts in our machining shop.

Y-BRANCH PIPE

Produktdaten

Unit weight: 200 kg
Material: EN GJS-400-15 (GGG40)
Batch size: 5 to 10 pieces

Target Setting

Fast and individual production, strict requirements for cast surface and dimensional accuracy of the casting.

Solution

Moulding boxes and auxiliary devices specially designed for this family of parts guarantee high process reliability so that customer requirements can be met.

Our Sand Casting
Capabilities

Cold-resin Block Moulding Plant
(Boxless)
  • Mould sizes 600 x 600 x 150/150 mm to 1200 x 1200 x 420/420 mm 
  • Batches of 10, 20, 50, 100 units
  • Part weights from 5 to 200 kg (rough casting weight)
  • Up to 100 cast iron and steel materials

    Automatic Core Block Moulding Machine

  • Mould sizes 400 x 400 x 400 mm /
    Ø 400 x 400 mm
  • Minimum batches of 60 moulds
  • Part weights from 1 to 20 kg (rough casting weight)
  • Up to100 cast iron and steel materials
Hand-moulding 
  • Largest box 2000 x 2000 mm
  • Small batches of 1 to 10 units
  • Part weights from 5 to 800 kg (rough casting weight)
  • Up to 100 cast iron and steel materials