Being a manual method of developing custom products, sand casting needs to be watched carefully for exceptional results. This is because the final product must not lose its mechanical properties despite the alloys and techniques used in the processes. A huge burden remains on the shoulders of the quality control personnel in such processes and they need to take care of a number of factors to get the job done efficiently. Here is a list of factors that clearly explain the significance of quality management in eco brass sand casting and other casting methods.
• Casting Finish: The surface finish of the object can be affected by a number of factors. It may be the type or quality of the molding sand, coating or method of cleaning. Such factors must be analyzed carefully for a perfect and smooth-surfaced cast. This involves a series of visual tests containing a number of models and usually the best one makes it out.
• Dimensional Accuracy: Slight change in the dimensions of a cast can affect its mechanical properties. This is the key difference between a useful and useless product. The mold cavity can expand or contract due to the pressure or temperature or it can just break. The best possible result in this aspect is also achieved by continuous efforts involving a number of casts. There are tolerances in the process as well but those have to be specified by the customer.
• Mechanical Properties: Ensuring the correct mechanical properties of a cast require mechanical testing. Mechanical testing involves hardness testing, tensile and impact testing, and service load testing. These processes ensure the life of a cast along with its weight and stress tolerance to give the right information to the end user. This is a critical step in the quality management process as it focuses more on the practical aspect of the cast despite its look and feel.
• Chemical Composition: The mechanical performance and the life of a cast largely depend on the alloy that is used in the process. The chemical performance of a cast is affected by even the minor alloying elements added to the metal. A detailed chemical analysis is required to properly check the right chemical composition for the alloy that ascertains the best possible quality and performance.
• Soundness: The casting soundness is not detected by the regular inspection as it requires the use of several non-destructive testing methods. This is because there are invisible flaws that require explicit attention. The methods include visual inspection, dimensional inspection, and chemical inspection such as dye penetrant and fluorescent powder testing. These tests ultimately determine the viability of the cast. And these are also essential for creating an end product that lasts to its life span without losing its effectiveness and mechanical performance.
About the Company
Gamma Foundries proudly provides its clients with access to 3D printing sand casting services. The company is one of Canada’s largest sand casting foundries, serving clients across the country and globe with design, development and production services. From single prototypes and one-offs to orders in the thousands, the company is equipped to deliver.