GAZİANTEP UNIVERSITY - ENGINEERING FACULTY

METALLURGICAL AND MATERIALS

ENGINEERINGS

2023/2024 SPRING SEMESTER

MET212: SOLIDIFICATION AND

CASTING

Experiment Title : Die casting versus sand casting

Student Number: 2020109011905

Prepared By : MUKHTAR AHMED

To: MUSTAFA HOCA

DATE: 4.06.2024
Introduction:
Casting is a popular manufacturing process with numerous industrial
applications because of its versatility, performance, and relatively lower cost.
The debate of die casting vs sand casting is quite common. Both processes
come with their set of advantages and disadvantages, so it’s hard to
determine a clear winner. In the end, the right process depends on your
overall requirements, design complexity, material properties, and other
important factors. In the crudest terms, the casting process melts metal and
puts the molten mixture in a pre-determined mold to give it shape. So why
are there so many kinds of casting processes and how are they different?
Most of the casting processes used today differ in the way the molten metal
is processed and settled in the mold. Two of the most common kinds of
casting are sand casting and die casting.

Background:
Determining the best casting process to use for manufacturing your next
cast aluminum part can be challenging. While there are many methods and
variants to choose from, two of the most commonly used processes are die
casting and sand casting.
These metal casting processes both offer a wide range of benefits to the
manufacturer, which can make it difficult to choose one over the other
without detailed knowledge of their qualities.
To understand which process between sand casting or die casting is better
for us , we need to know how they work and their differences. Knowing about
their intricacies, requirements, and results will help you make an informed.
choice and select the best process for your application.

So, let’s take a brief look at both the casting processes.

1 – What Is Die Casting

As its name suggests, the die casting process comes with the requirement of

a metal die that determines the final shape of the product. The process takes

place under extreme pressure and temperatures. The casting process

requires you to inject red-hot molten liquid into a metal mold where it’s left

to solidify for a short time. .

Die castings are made from non-ferrous metals such as zinc, copper,
aluminum, magnesium, lead, pewter, and tin.
The two methods of die casting are hot or cold chambers. The process that
is used depends on the type of metal and the part. The cold chamber
method is used with metals that have a high melting point such as alloys of
aluminum, brass, or copper. Hot chamber die casting is limited to metals that
won’t dissolve when heated such as zinc, lead, and magnesium alloys.

Once your product is complete, you can remove the item from the mold and
get ready for the next batch. Generally, the die casting process can take
from a few seconds to a few minutes depending on the size, shape, and
weight of the final [Link], you don’t have to recreate or destroy
the mold as you’ll be immediately ready for the next one. This quality, along
with the incredible processing speed of the process is among the biggest
factors when you study sand casting and die casting differences. That’s why
high-speed production environments always favor die casting.

2 – What Is Sand Casting

Sand casting is slightly different from die casting. You are still dealing with
molten metal that needs to be set in your desired shape, but there is no
pressure involved. The entire process of sand casting is at atmospheric
pressure where you develop your molds from sand and break them apart
later as well.
One of the biggest selling points of die casting is the immediate availability
of the mold. Sand casting doesn’t have that. The mold you create will require
around 10 minutes of preparation before they are ready for use.

This discrepancy makes sand casting a little less suitable for applications
where you need speed. However, the process is quite cost-effective and
versatile which makes it more suitable for alloys and unusual shapes.

You get more freedom because the process is simple, and can handle a
variety of alloys easily.

The Main Differences Between Sand Casting and Die Casting

Both sand and die casting are indeed an excellent choice for a variety of
situations. They are effective, relatively fast, and can give you the result you
need very soon. Therefore, deciding a clear winner while gauging sand
casting and die casting differences can be extremely [Link] are,
however, some key differences that are essential to consider while selecting
between the two casting methods. Knowing about them can help as you’ll be
in a better overall position to make an informed decision regarding the
process you select.
 Here are the key differences between sand and die casting processes.

1. MATERIAL USED TO MOLD:

The biggest difference between the two casting processes is the
material you use to make the mold. The die casting molds are metal
while sand casting molds are just like their name suggests, sand. This
means better overall results. Mechanical properties of sand cast vs die
cast parts are another important consideration that affects your
selection.
2. Complexity of Parts
While both methods can create complex part shapes, die casting is
often the preferred process for these types of casts. Thanks to pressure
injection of the molten aluminum, die casting can make components
with very thin walls. The pressure injection also leads to greater
dimensional accuracy for cast parts relative to sand casting.

3. Surface Finish
Another difference between sand casting and die casting is the surface
finish of castings made from these methods. Sand casting leaves
behind rough surfaces on parts because the compacted sand imprints
its texture onto the cast. Specialized sands and other measures can
reduce roughness, but this comes with extra cost. Die cast products,
however, boast a very high-quality surface finish due to both the
smoothness of the die’s inner walls and the pressure used to fill the
die.

Key Points Die Casting Sand Casting

Precision Higher Lower

Wall Thickness Thinner Ticker

Production Volume High Low

Surface Finish Excellent Not as good

Cost of Mold Higher Lower

Reusability of Mold Possible Not Possible

Possible and mostly easy to Difficult and mostly not

Complex Parts make possible.

The table below contains some more key comparisons between die cast and
sand :

Question: Is Aluminum Sand Casting Parts Better Than Aluminum Die

Casting Parts?

Manufacturers mostly use aluminum to make casting parts using different

casting methods such as sand casting and die cast. But the quality of
aluminum sand casting parts is not the same as aluminum die casting
[Link] can manufacture simple parts like gears, cylindrical metal bars,
pipes, etc. easily using sand casting aluminum alloys. However, you can
produce these parts with die cast as well. But if the parts are not made in
bulk then die casting of aluminum will cost a lot more than sand [Link]
the other hand, many complex aluminum parts such as air valves, engine
blocks, complex gears, etc. require to die cast. These parts are too difficult,
and in some cases impossible, to make with sand [Link], sand cast
aluminum parts tend to have more defects and poor surface finish compared
to die cast parts. So, they need more secondary machining after casting. But
if such a defect is not a big deal, then sand casting aluminum parts are
better because of the low [Link], aluminum die casting parts are
better because of having a good surface finish, fewer defects, and being
more precise.
Procedure:-

Step by step Process of Sand Casting:

1. Place Mold Pattern in Sand

2. Set Up the Gating System
3. Remove the Mold Pattern
4. Pour Molten Metal Into Mold Cavity
5. Wait for Metal to Cool
6. Break Open Mold to Remove the Metal Casting

Step by step Process of die Casting(metal mold casting):

1. Mould Design
2. Metal Preparation
3. Injection process
4. Casting process
5. Finishing process

 Note: both of our procedures sand casting and die casting we

melt aluminium in the oven (Heat an oven to about 700°C).

DISCUSSIONS AND RESULTS OF THE EXPERIMENT :

After performing the sand casting and die casting of aluminum, we proceeded with a series of
post-casting processes in the lab to prepare the samples for microscopic examination and
hardness testing. These steps included grinding, polishing, etching, and finally, conducting
microscopic and hardness tests to compare the characteristics of the aluminum samples produced
by each casting method.

1. Grinding:
o The cast aluminum samples were first subjected to grinding. This
step was essential to remove any surface irregularities and to
achieve a smooth and flat surface. Coarse grit silicon carbide
 papers were used initially, followed by progressively finer grits to
achieve a uniform surface suitable for polishing.

2. Polishing:
o After grinding, the samples were polished to produce a mirror-like
finish. This was done using a series of polishing cloths with
progressively finer diamond suspensions or alumina slurries. The
goal of polishing is to eliminate any remaining surface scratches
and to prepare the samples for etching and microscopic
examination.

3. Etching:
o The polished samples were then etched using an appropriate
etching solution for aluminum. Common etching solutions include
Keller's reagent (comprising nitric acid, hydrochloric acid,
hydrofluoric acid, and water) or similar formulations. Etching
enhances the visibility of the microstructural features by
selectively corroding different phases or grain boundaries in the
aluminum.

Microscopic Examination

 Following etching, the samples were examined under a microscope.

This allowed us to observe the microstructure of the aluminum,
including grain size, shape, and any casting defects such as porosity
or inclusions. The microstructure can provide insights into the cooling
rates and solidification processes associated with each casting
method.

1. DIE CASTING (metal mold casting )GRAIN SIZE :

 2. SAND CASTING GRAIN SIZE :

:- note: : The microstructure of sand-cast samples of aluminium showed

larger grain sizes and more porosity compared to die-cast samples.
Hardness Testing:

 Finally, the hardness of each sample was measured using a hardness

tester. This involved indenting the sample with a specified force and
measuring the size of the indentation to determine the hardness
value. Hardness testing helps assess the mechanical properties of the
cast aluminum and any differences resulting from the casting method
used.

Table below shows us sample of hardness testing done by hardness

tester by applying load of (0.2kg) by Dwell time(10seconds):

Die casting Sand casting

hardness 353.3 465.5
hardness 1307.5 778.3
hardness 2410.4 1417.2
Average 1357.06 887

NOTE: AS The results of hardness testing showing die casting of

aluminium is harder than the sand casting aluminium.

Comparison of Sand Casting and Die Casting:

1. Sand Casting

 Surface Finish: The sand-cast aluminum samples typically exhibited a

rougher surface finish due to the sand mold texture. This required
more extensive grinding and polishing to achieve a smooth surface.
 Microstructure: The microstructure of sand-cast samples often showed
larger grain sizes and more porosity compared to die-cast samples.
This is due to the slower cooling rates and the nature of the sand mold.
 Hardness: The hardness of sand-cast samples was generally lower and
more variable due to the presence of casting defects and larger grain
sizes.
 2. Die Casting

 Surface Finish: Die-cast aluminum samples had a much smoother

surface finish right out of the mold, requiring less grinding and
polishing.
 Microstructure: The microstructure of die-cast samples was
characterized by finer grains and fewer casting defects. The high
pressure and rapid cooling rates associated with die casting contribute
to this refined microstructure.
 Hardness: Die-cast samples typically exhibited higher and more
consistent hardness values due to the finer microstructure and reduced
porosity.

Conclusion:-
The comparison between sand casting and die casting of aluminum revealed
significant differences in surface finish, microstructure, and hardness. Die
casting generally produced superior results in terms of surface smoothness,
microstructural refinement, and mechanical properties. However, sand
casting remains valuable for producing larger and more complex shapes at a
lower cost for lower production volumes.

These findings underscore the importance of selecting the appropriate casting method based on
the specific requirements of the aluminum parts being produced, considering factors such as part
size, complexity, production volume, and desired mechanical properties.

Refrences:

[Link]

Book: Herman, F. (2015). Die Casting Engineer's Handbook. NADCA.

Book: ASM International. (2004). Metallographer's Guide: Practices and

Procedures for Irons and Steels. ASM International.

 Book: Wilson, D. V., & Bullough, R. (1978). Hardness Testing. ASM International.
[Link]