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

CLAMPING FRAME

Characteristics

Unit weight: 50 to 100 kg
Material: G-X 22 CrNi 17 (1.4059)
Batch size: 20 to 100 pieces

Target Setting

Strict requirements for dimensional accuracy and freedom from distortion, cast steel suitable for surface hardening.

Solution

Precise mould production and close monitoring of casting parameters provide the basis for meeting the very strict requirements for dimensional accuracy, freedom from distortion and material properties.

TURBINE INTAKE HOUSING

Characteristics

Unit weight: 50 to 1.200 kg
Material: EN GJS-XSiMo 4.05 (SiMo iron)
Batch size: 5 to 30 pieces

Target Setting

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

Solution

Mould boxes specially designed for this family of parts and feed and casting system specially suited to the silicon an molybdenum alloy material ensure high process reliability so that customer requirements are met. Constant monitoring of the melt and the metallurgical parameters ensures continuous quality of this refractory cast iron.

BOLT HOLDER

Characteristics

Unit weight: 5.7 kg, Dimensions: 225 x 140 x 80 mm
Material: EN-GJS-400-18-LT (EN-JS1025) (previously GGG-40.3)
Batch size: 100 to 500 pieces
Delivered with inspection certificate

Target Setting

This latch fastening for railway points has a high level of toughness even at low temperatures.

Solution

Nodular iron on moulding plant. This material ensures notch impact energy at minus 20 °C. Supplied as ferritic annealed raw castings with inspection certification in compliance with EN 10 204-3.1 concerning composition, tensile strength and notch impact energy.

Z-Rail

Produktdaten

50 versions, length: 120 mm to 900 mm
Verschleissbeständiges alloyed cast iron - various alloys.
Batch sizes: 2-50 pieces
ready for installation

Targe

Very high wear resistance, very tight tolerances on difficult to machine materials, fast delivery is ensured through framework agreements.
solution

Solution

These blanks are cast using the sand casting method on our cold resin molding plant or small quantities in the core block method. The original design of the parts was constructed as a steel bar with carbide inserts, high failure and wear caused our customers to search for a new method and Wolfensberger. From our specialized experience with casting and machining WEAR materials developed solutions with special processing steps: the parts are annealed to 28-32 HRC, pre-processed, cured under vacuum at 62 to 64 HRC and finally ground with diamond wheels to the final mass or eroded into sublots. The customer trusts us to also blanks made ​​of tungsten carbide, technical ceramics, for this demanding processing; the tolerances of individual mass lie in the range of hundredths. Delivery can be done within a maximum of pre-finished five days after ordering. Depending on the plant one of the 50 variants will be retrieved. Our client has changed the whole structure of this method and now holds only a small stock.

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