1. Bellwood-Antis Technology Education Department Bellwood-Antis High School Mr. Mackereth Mr. Crowell

2.  Sand casting has THREE ADVANTAGES compared to other casting methods:  (1) Sand casting is easier for shop students to make high quality castings.  (2) The casting sand is reusable over and over again if properly maintained  (3) Sand casting is relatively inexpensive to make the casting molds.

3.  Mold- A cavity or opening in the sand the size & shape of the desired item.  Pattern- The object placed in sand (then removed) to form the cavity in the mold.  Flask- A two-piece container that holds the sand mold in place for pouring.  Cope- The TOP half of the flask.  Drag- The BOTTOM half of the flask

4.  Parting Compound- A very fine silica powder that allows for separation of the cope & drag when removing the pattern  Riser & Sprue- Vertical “tube” openings where metal is poured into the mold  Runners & Gates- Openings between pattern pieces in the mold providing a smooth path for the flow of molten metal

5.  Bench Rammer  Flask (2 pieces)  Cope (top half)  Drag (bottom half)  Crucible Furnace  Crucible  Gate Cutter  Bellows  Sprue & Riser  Riddle  Slick & Oval  Strikeoff Bar  Trowell  Parting Compound PLEASE REFER TO THE ATTACHED DIAGRAM IN YOUR NOTEBOOK

6.  (1) Place the DRAG on a molding board UPSIDE DOWN (with pins pointing down)  (2) Place the PATTERN PIECE(S) down on the on the molding board.  (3) LIGHTLY sprinkle the board and pattern with PARTING COMPOUND.  (4) Cover the pattern with 1” of FINELY SIFTED SAND through the RIDDLE.

7.  (5) PACK sifted sand around the pattern with a BENCH RAMMER. PACK FIRM!  (6) Place MORE SAND in the drag, and pack it FIRMLY with a bench rammer.  (7) When packed full to the top, clean off the sand with the STRIKEOFF TOOL.  (8) CAREFULLY flip the drag RIGHT SIDE UP on the bottom board.

8.  (1) Place the COPE on the top of the DRAG (line up the pins & holes.)  (2) Sprinkle PARTING COMPOUND LIGHTLY on the other side of the pattern.  (3) Insert the SPRUE and RISER tubes into the packed sand in the drag.  (4) Cover the pattern with at least 1” of finely sifted sand through the RIDDLE.

9.  (5) CAREFULLY PACK sifted sand with bench rammer. Also pack around the sprue & riser.  CAUTION: DO NOT PACK THE COPE TOO MUCH! It will sink the pattern pieces down into the drag half of the mold  (6) Place more sand in the cope, and pack it firmly with the bench rammer.  (7) When packed to the top of the cope, clean off the sand with the STRIKEOFF TOOL.

10. ((1) CAREFULLY remove the COPE and set it on its side off to the side. CAREFULLY ! ! ! ((2) Cut GATES & RUNNERS (A COMPLETE PATH) through the sprue, pattern, & riser. ((3) MAKE SURE GATES / RUNNERS WILL GIVE YOU A GOOD FLOW! ((4) CAREFULLY remove the pattern from the DRAG half of the mold.

11.  (5) Firm up any weak spots in the sand with the TROWEL and the SLICK & OVAL.  (6) Blow away any loose sand with the BELLOWS & clean the edge of the drag.  (7) Make a FINAL CHECK of the mold & CAREFULLY place cope on top of drag.  (8) CAREFULLY set the mold on the floor. The teachers will pour at a later time.