Resin Sand Casting

Resin Sand Casting Foundry

Resin sand casting is to mix raw sand, resin and curing agent evenly and put them into the sandbox and pattern to make the core. It uses furan resin and curing agent to make the sand compact and hard enough. Then close the box for raw casting. Resin sand casting involves uniformly mixing raw sand, resin, and a hardener, then placing the mixture into a sand mold and pattern to create the core. After assembling the mold, the casting is performed; this process is also called cold-curing resin sand molding. Unlike coated sand, which hardens through heat, resin sand is self-hardening sand, also known as cold-curing sand, and hardens with a hardener.

Resin sand casting is particularly suitable for large cast steel parts with limited quantity requirements. Resin sand refers to molding sand or core sand that uses synthetic resin as a binder for the sand particles. After the mold or core is made with resin sand, the resin undergoes an irreversible cross-linking reaction and solidifies under the action of a hardener, thus giving the mold or core strength. The dimensional accuracy of resin sand casting is slightly lower than that of coated sand.

Resin Sand Casting

Capacities and Molten Metal for Resin Sand Castings

▶Ferrous and Non-Ferrous Metals for Resin Sand Castings

• Gray Cast Iron:  EN-GJL-100, EN-GJL-150, EN-GJL-200, EN-GJL-250, EN-GJL-300, EN-GJL-350
• Ducitle (Nodular, Spheroidal Graphite) Iron: EN-GJS-400-18, EN-GJS-40-15, EN-GJS-450-10, EN-GJS-500-7, EN-GJS-600-3, EN-GJS-700-2, EN-GJS-800-2
• Cast Aluminium and Their Alloys
• Alloy steel or carbon steel or other materials and standards on request
• Brass, Bronze and other Copper-based Alloys

• Max Size of Casting Molds: 1,500 mm × 1000 mm × 500 mm
• Weight Range of Resin Sand Castings: 0.5 kg - 500 kg
• Annual Capacity of Resin Sand Castings: 5,000 tons - 6,000 tons
• OEM Custom Services: Available
• Casting Tolerances: On Request.

Metal Foundry

How We Inspect Resin Casting Castings

Our Spectrometer checks 15 chemical elements and metallurgical microscope produces high-resolution images 1,000 times magnified, and our cleanliness meter determines particle size and quantity to ensure materials meet or exceed the international standard. RMC use ultrasonic detectors to discover flaws, and have X-ray machines and accelerators that can scan castings with 200 mm maximum wall thickness.

RMC has a full range of inspection capabilities in house, which include:

1. Spectrographic and manual quantitative analysis
2. Metallographic analysis
3. Brinell, Rockwell and Vickers hardness inspection
4. Mechanical property analysis
5. Low and normal temperature impact testing
6. Cleanliness inspection
7. UT, MT and RT inspection

Coordinate Measuring Machine (CMM)

Resin Sand Casting Procedures

1- Design and Make Patterns.

The resin sand needs to be heated in the patterns, so metal patterns are the necessary tooling to make shell molding casting

2- Make Sand Mold

After installing the metal patterns on the molding machine, the resin sand will be shot into the patterns, and after heating, the resin coating will be molten, then the sand molds become solid sand shell and cores.

3- Melt the Cast Metal

Using induction furnaces, the materials would be melted into liquid, then the chemical compositions of the liquid iron should be analyzed to match the required numbers and percents.

4- Pouring Molten Metal

When the melted iron meet the requirements, then they will be poured into the shell molds. Based on different characters of the casting design, the shell molds will be buried into green sand or stacked up by layers.

5- Shot Blasting, Grinding and Cleaning

After the cooling and solidification of the castings, the risers, gates or additional iron should be cut off and removed. Then the iron castings will be cleaned by sand peening equipment or shot blasting machines. After grinding the gating head and parting lines, the finished casting parts would come, waiting for the further processes if needed.

Molds for Resin Sand Casting

Resin Sand Casting Workshop

Resin Sand Casting Foundry Gallery

In RMC's foundry, we utilize the professional equipment to produce the patterns and form the casting shell mold. These highly organized equipment help us to produce the resin sand castings part of high quality and big volume. These equipment could produce diverse custom castings such as grey iron castings, ductile iron castings, carbon steel castings, alloy steel castings, stainless steel castings, aluminium castings and brass castings.

Applications of Resin Castings

Resin sand castings could serve in many industries including gearboxes, industry valves, pumps, hydraulics, automotive, commercial truck, rail trains, logistics, agricultural machinery...etc. The castings mainly are used as gearbox housing, gearbox cover, pump housing, pump cover, cylinder heads, transmission box, brackets, wheel hub, connecting rods, axles and manifolds...etc.

Typical Resin Sand Castings

Value Added Services from Resin Sand Casting Foundry at RMC

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 with under the help of the software of 3D and CAD drawings and simulations software. From start to finish, we have you covered every step of the way.

• Heat treatment: Quenching, Tempering, Normalizing, Annealing, Carburization, Nitration
• Surface treatment: Anodizing, Zinc-plating, Polising, GeoMet, Zintek, Electrophoresis....etc
• Testing Service: Chemical Composition, Mechanical Properties, Fluorescent or Magnetic Penetration Inspections (FPI, MPI), X-rays, Ultrasonic Testing, Dynamic and Static Balancing Testing

RMC offers a full range of resin sand casting solutions. If you would like to know more about our technology and resin sand casting process capabilities, contact us today.

Warehouse at RMC Sand Casting Foundry