Green Sand Casting, Green sand casting foundry in india, Bronze Green Sand Casting, Lg2 Green sand casting, Red Brass Casting, C360 Green sand Casting, Ductile Iron Green sand casting

 

 

Bronze  Green sand casting- Price: $ 11/Kilogram

Green Sand Casting Services

Premium Foundry Solutions for Global Industry

Green sand casting represents one of the most versatile and economical casting processes available in modern manufacturing. We are one of the leading manufacturers and exporters of precision green sand castings from Jamnagar, India. We have been supplying high-quality metal castings to the world market for many decades. Our extensive experience spanning three decades has established us as a trusted partner for industries requiring reliable, dimensionally accurate castings across multiple material grades including Bronze, Brass, and Ductile Iron. Our foundry combines traditional craftsmanship with modern manufacturing processes to deliver castings that consistently meet international standards while maintaining competitive pricing and exceptional quality control. We pride ourselves on our ability to handle both high-volume production runs and specialized custom castings with equal precision and attention to detail.

Green Sand Casting Process

Green sand casting utilizes a mixture of silica sand, clay (typically bentonite), water, and additives to create a moldable medium that can accurately capture complex part geometries. The term “green” refers not to the color but to the moisture content present in the sand mixture.

Our process employs the following sequence:

Process Stage	Description	Quality Controls
Pattern Making	Creation of wooden, metal or resin pattern	Dimensional verification with CMM
Mold Preparation	Sand mixing, ramming and compaction	Permeability testing, moisture control
Core Setting	Placement of cores for internal features	Core hardness testing
Melting	Alloy preparation to exact composition	Spectrographic analysis
Pouring	Controlled introduction of molten metal	Temperature monitoring
Cooling & Shakeout	Solidification and sand removal	Cooling curve analysis
Finishing	Shot blasting, grinding, machining	In-process inspection
Testing	Dimensional, metallurgical and performance tests	Documentation and certification

The green sand casting process offers significant advantages including cost-effectiveness, material flexibility, and suitability for both small and large production runs. Our foundry maintains precise control over all process variables to ensure consistent quality across all castings.

Green Sand Casting Foundry in India

Our state-of-the-art foundry facility in India spans over 50,000 square feet and employs more than 200 skilled technicians and metallurgists. The facility incorporates modern melting furnaces, advanced pattern-making equipment, automated molding lines, and comprehensive testing laboratories.

Foundry Capabilities:

• Annual production capacity of 5,000 metric tons
• Maximum casting weight: 500 kg single piece
• Minimum casting weight: 0.1 kg
• Pattern development capabilities with in-house pattern shop
• Comprehensive machining facilities for finished components
• ISO 9001:2015, ISO 14001:2015, and IATF 16949 certified

Technical Infrastructure:

• Medium frequency induction furnaces (500 kg to 2 tons capacity)
• Automated green sand molding lines
• Mechanical and pneumatic molding machines
• Core making facilities with cold box and shell core processes
• Spectro analysis equipment for precise composition control
• Fully equipped metallurgical laboratory
• Advanced heat treatment facilities

Our unique ability to combine traditional foundry expertise with modern manufacturing technology allows us to produce castings that meet the most demanding international standards while maintaining competitive pricing. We serve clients across North America, Europe, Australia, and Asia, with particular expertise in the automotive, pump and valve, electrical, and industrial machinery sectors.

Bronze Green Sand Casting

Bronze alloys represent some of the most versatile and widely used materials in precision casting applications. Our foundry specializes in producing high-quality Bronze castings through the green sand process, offering exceptional wear resistance, corrosion resistance, and mechanical properties.

Bronze Grades Available:

Alloy Designation	Common Name	Composition	Key Properties
C83600	85-5-5-5 Bronze	85% Cu, 5% Sn, 5% Pb, 5% Zn	Excellent machinability, good corrosion resistance
C90300	Tin Bronze	88% Cu, 8% Sn, 4% Zn	High strength, good bearing properties
C90500	Gun Metal	88% Cu, 10% Sn, 2% Zn	Excellent wear resistance, high pressure tightness
C91100	High-Strength Bronze	84% Cu, 16% Sn	Superior strength and hardness
C93200	SAE 660	83% Cu, 7% Sn, 7% Pb, 3% Zn	Superior bearing properties
C95400	Aluminum Bronze	85% Cu, 11% Al, 4% Fe	Exceptional strength and corrosion resistance

Our Bronze castings comply with international standards including ASTM B584, BS 1400, DIN 1705, and JIS H5120. We maintain precise control over alloying elements and casting parameters to ensure consistent mechanical properties.

Typical Bronze Casting Applications:

• Marine components (propellers, rudders, seawater valves)
• Pump and valve bodies for corrosive environments
• Hotline clamps in Bronze
• Bearing housings and bushings
• NEMA spacing Transformer Spades Transformer Spade Connectors 
• Gear blanks and worm wheels
• Decorative architectural elements
• Bronze Electrical Connectors Vise Connectors

Our Bronze castings undergo rigorous testing including chemical analysis, mechanical testing, pressure testing, and non-destructive examination as required by customer specifications.

LG2 Green Sand Casting

LG2 Bronze (BS 1400 LG2 / C90300) represents one of the most versatile and widely specified gunmetal alloys in engineering applications. This high-quality tin Bronze provides an excellent balance of strength, corrosion resistance, and pressure tightness that makes it ideal for fluid handling applications.

LG2 Bronze Composition and Properties:

Element	Percentage	Property	Typical Value
Copper	85-88%	Tensile Strength	240-310 MPa
Tin	9-11%	Yield Strength	120-170 MPa
Zinc	2-4%	Elongation	12-20%
Lead	0.5-1.5%	Hardness	75-95 HB
Nickel	1.0% max	Density	8.8 g/cm³
Iron	0.2% max	Melting Range	1000-1050°C

Key Features of Our LG2 Castings:

• Excellent resistance to seawater corrosion
• Superior pressure tightness for hydraulic applications
• Good machinability for secondary operations
• Excellent anti-friction properties
• Suitable for applications up to 200°C
• Compliance with BS 1400 LG2 and ASTM B505 C90300 standards

LG2 Casting Applications:

Our LG2 Bronze castings are extensively used in marine and industrial fluid handling applications including:

• Marine valves and fittings
• Pump components for corrosive media
• Steam and water fittings
• Hydraulic equipment
• Chemical processing equipment
• Gears and worm wheels

We maintain precise control over the alloying elements in our LG2 Bronze castings, with particular attention to tin content to ensure optimal mechanical properties. All castings undergo rigorous testing and inspection before shipment.

Red Brass Green Sand Casting

Red Brass alloys, known for their distinctive reddish color and excellent corrosion resistance, represent a significant portion of our production capabilities. Our green sand casting process is perfectly suited to producing complex Red Brass components with excellent surface finish and dimensional accuracy.

Red Brass Grades:

Alloy Designation	Common Name	Composition	Applications
C83300	Leaded Red Brass	93% Cu, 7% Pb	Plumbing fixtures, decorative hardware
C83400	Leaded Semi-Red Brass	92% Cu, 8% Pb	Low-pressure valves, general hardware
C83600	Ounce Metal	85% Cu, 5% Sn, 5% Pb, 5% Zn	Plumbing goods, pump components
C84400	Semi-Red Brass	81% Cu, 3% Sn, 7% Pb, 9% Zn	Valve bodies, pipe fittings
CA 833	Red Brass Special	85% Cu, 5% Sn, 5% Zn, 5% Pb	Electrical components, switchgear parts

Technical Specifications:

Our Red Brass castings comply with international standards including ASTM B584, BS 1400, and DIN 1705. The green sand casting process is particularly well-suited for Red Brass alloys, producing castings with:

• Excellent pressure tightness (up to 35 kg/cm² without porosity)
• Superior corrosion resistance, particularly to dezincification
• Good machinability (85-90% rating compared to free-cutting Brass)
• Surface finish of 125-250 RMS before machining
• Dimensional tolerance of ±0.8mm for first 25mm and ±0.4mm for each additional 25mm

Manufacturing Considerations:

Red Brass requires specific foundry controls which we maintain through:

• Careful melt temperature control (typically 1050-1100°C)
• Optimal gating and risering design to prevent shrinkage
• Controlled cooling to prevent hot tears
• Special degassing procedures to ensure pressure tightness

Typical applications for our Red Brass castings include plumbing fittings, pump components, valve bodies, marine hardware, and decorative architectural elements.

Ductile Iron Green Sand Casting

Ductile Iron (also known as Spheroidal Graphite Iron or Nodular Iron) combines the castability of gray iron with mechanical properties approaching those of steel. Our green sand casting process for Ductile Iron delivers exceptional strength, ductility, and toughness in complex components.

Ductile Iron Grades:

Grade	International Equivalent	Tensile Strength (MPa)	Yield Strength (MPa)	Elongation (%)	Typical Applications
GGG-40	ASTM A536 60-40-18	400	250	18	General engineering, pipe fittings
GGG-50	ASTM A536 70-50-05	500	320	7	Automotive components, machinery parts
GGG-60	ASTM A536 80-60-03	600	370	3	Crankshafts, connecting rods
GGG-70	ASTM A536 100-70-03	700	420	2	Highly stressed components
GGG-80	–	800	480	2	Safety-critical components

Production Process Specifics:

Our Ductile Iron casting involves specialized process controls:

1. Base iron preparation with precise carbon and silicon control
2. Magnesium treatment using covered ladle or in-mold methods
3. Inoculation to ensure optimal nodule formation
4. Careful temperature control during pouring (1380-1420°C)
5. Modified gating and risering compared to gray iron to account for higher shrinkage
6. Specialized heat treatment when required

Quality Assurance:

Every batch of Ductile Iron undergoes extensive testing:

• Metallographic examination for nodularity (>80% required)
• Mechanical testing (tensile, yield, elongation)
• Hardness testing (typically 170-270 BHN depending on grade)
• Dimensional inspection using CMM where required
• Ultrasonic testing for critical components

Common Applications:

Our Ductile Iron castings serve diverse industries including:

• Automotive (crankshafts, steering knuckles, differential cases)
• Agricultural equipment (gears, housings, brackets)
• Pump and valve components requiring pressure tightness
• Infrastructure components (manhole covers, pipe fittings)
• Industrial machinery (gears, housings, brackets)

C360 Bronze Green Sand Casting

C360 Bronze (also known as Leaded Commercial Bronze) combines excellent machinability with moderate strength and good corrosion resistance. Our green sand casting process is optimized for producing high-quality C360 components with excellent surface finish and dimensional accuracy.

C360 Bronze Composition and Properties:

Element	Percentage	Property	Typical Value
Copper	60-63%	Tensile Strength	310 MPa
Zinc	35-38%	Yield Strength	140 MPa
Lead	2-3%	Elongation	30%
Iron	0.35% max	Hardness	65-75 HRB
Other	0.5% max	Density	8.5 g/cm³

Processing Considerations:

C360 Bronze presents specific considerations in green sand casting:

• Pouring temperature maintained at 950-1050°C
• Special gating designs to accommodate the fluidity characteristics
• Modified risering to address shrinkage behavior
• Controlled cooling to prevent defects
• Special finishing procedures to achieve optimal surface appearance

Typical Applications:

Our C360 Bronze castings excel in applications requiring:

• Excellent machinability for complex features
• Moderate strength with good ductility
• Good corrosion resistance
• Dimensional precision
• Economical production

Common applications include plumbing components, electrical hardware, decorative architectural elements, and general engineering components where ease of machining is a primary consideration.

Manufacturing Capabilities

Our green sand casting operation incorporates comprehensive capabilities from initial design consultation through to finished components:

Pattern Equipment:

• In-house pattern making using hardwood, aluminum, or resin
• Pattern modification and repair services
• Digital pattern design using CAD/CAM technology
• 3D printing for rapid prototyping of patterns

Molding Capabilities:

• Manual molding for specialized or low-volume work
• Semi-automated jolt-squeeze machines
• High-pressure molding lines for production quantities
• Specialized core making facilities
• Maximum mold size: 1000mm x 800mm x 350mm

Melting Facilities:

• Medium frequency induction furnaces
• Crucible furnaces for specialized alloys
• Precise temperature control systems
• Metallurgical analysis for composition control

Finishing Operations:

• Shot blasting and cleaning
• Heat treatment facilities
• Grinding and fettling
• CNC machining capability
• Pressure testing facilities
• Coating and painting options

Inspection and Testing:

• Fully equipped metallurgical laboratory
• Dimensional inspection using CMM
• Mechanical testing (tensile, impact, hardness)
• Pressure testing capabilities
• Non-destructive testing (radiography, dye penetrant)

Typical Parts Produced

Our green sand casting process creates components for diverse industries including:

Valve and Pump Industry:

• Valve bodies (gate, globe, check, ball)
• Pump casings and impellers
• Pressure-containing housings
• Flow control components

Automotive and Transportation:

• Brake components
• Transmission housings
• Engine brackets
• Steering components
• Suspension parts

Industrial Machinery:

• Gear housings
• Bearing blocks
• Motor housings
• Structural components
• Drive system components

Electrical and Power Generation:

• Transformer components
• Switchgear housings
• Junction boxes
• Bus bar supports

Marine Applications:

• Propellers
• Rudder components
• Seawater valves
• Hull fittings

Industry	Typical Parts	Material Preferences	Special Requirements
Valve & Pump	Valve bodies, pump casings	Bronze, Brass, Ductile Iron	Pressure tightness, corrosion resistance
Automotive	Engine brackets, transmission parts	Ductile Iron, Aluminum	Strength, weight reduction
Industrial	Gearboxes, bearing housings	Cast Iron, Bronze	Wear resistance, dimensional stability
Marine	Propellers, seawater components	Bronze, particularly LG2	Salt water corrosion resistance
Electrical	Switchgear, junction boxes	Bronze, Brass	Electrical conductivity, flame resistance

Tolerances and Specifications

Our green sand casting process achieves the following standard tolerances:

Linear Dimensions:

Casting Dimension (mm)	Standard Tolerance (mm)	Precision Grade Tolerance (mm)
Up to 50	±1.0	±0.8
51-100	±1.5	±1.0
101-200	±2.0	±1.5
201-300	±2.5	±2.0
301-500	±3.0	±2.5
>500	±4.0	±3.0

Surface Finish:

• Standard: 150-250 RMS
• Precision: 125-200 RMS

Machining Allowances:

• Standard: 2-3mm per surface
• Precision: 1.5-2mm per surface

All castings are produced in accordance with applicable international standards including:

• ASTM A48, A536, B584, B505
• ISO 1083, 185
• DIN 1691, 1693, 1705
• BS 1452, 1400
• JIS G5501, G5502, H5120

Turnaround Time and Production Capabilities

Our foundry operates with flexible production scheduling to accommodate both standard and urgent requirements:

Standard Lead Times:

• Pattern development: 3-4 weeks
• First article samples: 4-5 weeks from pattern approval
• Production runs: 4-6 weeks from sample approval

Rush Service Options:

• Expedited pattern development: 2-3 weeks
• Fast-track sampling: 2-3 weeks
• Accelerated production: 3-4 weeks

Production Volume Capabilities:

• Prototype quantities: 1-10 pieces
• Small production runs: 10-100 pieces
• Medium production: 100-1,000 pieces
• High volume: 1,000+ pieces

Our manufacturing planning system allows for just-in-time production scheduling and kanban-based inventory management for regular customers.

Why Choose Our Green Sand Casting Services

Our foundry offers several distinct advantages that differentiate us in the global casting market:

Technical Excellence:

• Three decades of foundry experience across multiple alloy systems
• Comprehensive metallurgical expertise
• Advanced process controls for consistent quality
• Ability to cast complex geometries with excellent dimensional accuracy

Business Advantages:

• Competitive pricing structure with transparent quotation process
• Flexible production scheduling to accommodate urgent requirements
• Comprehensive documentation and certification
• Multi-language technical support (English, German, Spanish, Japanese)

Quality Assurance:

• ISO 9001:2015 certified quality management system
• Consistent material properties through rigorous process controls
• Comprehensive inspection and testing protocols
• Full traceability from raw materials through finished product

Customer Support:

• Dedicated technical account managers for each client
• Design assistance for casting optimization
• Regular production updates and communication
• Collaborative problem-solving approach

Global Logistics:

• Experienced in international shipping and documentation
• Custom packaging to client specifications
• Consolidated shipping options for cost efficiency
• Just-in-time delivery programs for regular customers

Frequently Asked Questions

Q: What is the minimum order quantity for your castings? A: While we specialize in medium to high-volume production, we can accommodate orders as small as 10 pieces for established patterns. For new patterns, we typically recommend a minimum of 25 pieces to amortize pattern costs effectively.

Q: Can you provide machined castings ready for assembly? A: Yes, we offer comprehensive machining services including CNC turning, milling, drilling, and threading. We can deliver components machined to print specifications, reducing your supply chain complexity.

Q: How do you ensure consistent quality across production batches? A: We maintain rigorous process controls including spectrographic analysis of each melt, standardized molding parameters, and comprehensive dimensional and metallurgical testing of production samples throughout the manufacturing run.

Q: What international standards do your castings comply with? A: Our castings comply with relevant international standards including ASTM, ISO, DIN, BS, and JIS specifications. We can also work to proprietary customer specifications when required.

Q: Can you assist with casting design optimization? A: Absolutely. Our engineering team has extensive experience in casting design and can provide recommendations to improve castability, reduce defects, and optimize material usage without compromising component functionality.

Q: What documentation do you provide with your castings? A: Standard documentation includes material certificates, dimensional inspection reports, and compliance certificates. We can also provide additional documentation such as radiographic results, pressure test reports, and material traceability documentation as required.

Q: How do you handle intellectual property protection for proprietary designs? A: We maintain strict confidentiality protocols and can execute Non-Disclosure Agreements (NDAs) before beginning any project. Our systems ensure pattern and drawing security throughout the production process.

Q: What are your shipping terms for international orders? A: We offer flexible shipping terms including EXW, FOB, CIF, and DAP. For regular customers, we can establish customized logistics programs to optimize shipping costs and delivery timing.

Q: Can you handle rush orders or expedited production? A: Yes, we maintain production capacity flexibility to accommodate urgent requirements. Rush service fees may apply, but we work closely with customers to meet critical deadlines.

Q: What payment terms do you offer? A: For new customers, we typically require 50% advance payment with order and 50% before shipment. For established customers, we offer 30-day net terms after credit approval. We accept payment via wire transfer, letter of credit, or through secure online payment systems.

Customer Testimonial

“We’ve been sourcing Bronze valve components from this foundry for over five years now, and they’ve consistently delivered exceptional quality. Their technical expertise helped us optimize our designs for better castability, which reduced costs without compromising performance. What impresses me most is their communication and reliability – they’re truly a partner rather than just a supplier. I can’t recommend them highly enough for precision copper alloy castings.”

– Robert Anderson, Purchasing Director,  USA

Related Terms

• Sand casting
• Green sand molding
• Foundry processes
• Metal casting
• Non-ferrous casting
• Ferrous casting
• Bronze casting
• Brass foundry
• Ductile iron production
• Investment casting
• Die casting
• Permanent mold casting
• Pattern making
• Core making
• Gating system design
• Risering techniques
• Metal casting defects
• Cast part machining
• Cast metal finishing
• Heat treatment of castings

Glossary of Terms

Bentonite: Clay mineral used as a binder in green sand mixtures that provides strength and plasticity to the molding material.

Casting: The process of pouring molten metal into a mold to create a metal object of a desired shape.

Cope: The upper half of a two-part flask used in sand casting.

Core: A separate part of the mold that creates internal features or undercuts in the casting.

Drag: The lower half of a two-part flask used in sand casting.

Draft: The taper applied to vertical surfaces of a pattern to facilitate its removal from the sand mold.

Flask: The frame that contains the molding sand during the casting process.

Gate: The channel through which molten metal enters the mold cavity.

Green Strength: The strength of a molding sand mixture in its moist (green) state before drying or baking.

Parting Line: The surface where the cope and drag meet in a two-part mold.

Pattern: A replica of the object to be cast, used to create the cavity in the molding material.

Permeability: The ability of molding sand to allow gases to escape during casting.

Riser: A reservoir of molten metal that feeds the casting as it solidifies and shrinks.

Runner: The channel that connects the sprue to the gates.

Sprue: The primary channel through which molten metal enters the mold.

Vent: A small channel created in the mold to allow gases to escape during pouring and solidification.

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A1metallics – Precision Castings for Global Industry