Sow moulds are reusable, cast steel moulds used to form aluminium ingots and empty molten metal from furnaces and transfer launders.
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Rich Experience
Xian aL-sT Is found in 1996, Also supply mechanical products（parts) to the automotive industry, railways, oil exploration, mining, and construction for more than 27 years. Our dross press was designed by a guru in the aluminum industry for more than 40 years of experience, who has more than 250 sets of dross press installation experience.
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Dross pan as Casthouse consumable to maximizes your recovery both on site and at the secondary processor.
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We have applied our sucessful experience to business of mechnical products (including parts) into the fields for applications in the automotive industry, railways, oil exploration, mining, Agriculture, Cement and Concrete product manufacturing, pulp, paper and paperboard mills and construction equipment too.
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One-stop solution for Metal Recyling Industries-Aluminum production ranging from primary production to value added products to recycling, as well as suppliers to the industry.
How Do Sow Molds Work for Metal Casting?
Sow Moulds are utilized in metal casting processes to create intricate and customized components. The following outlines the working principles of sow molds for metal casting:
Creation of Mold Cavity: Sow molds begin by packing sand around a pattern to form the mold cavity. The sand is typically contained within a cope and drag, which represent the top and bottom halves of the mold. Once the cavity is formed, the pattern is removed, leaving its impression in the sand.
Assembly and Pouring: After the example is eliminated, the mold is collected, and liquid metal is filled the hole space. As the metal cools and hardens, it takes on the state of the sand mold, making a nitty gritty and exact proliferation of the first example.
Porosity and Gas Escape: The porosity of the packed sand allows gases and steam to escape as the metal undergoes shrinkage during solidification. This capability is advantageous over closed permanent molds, as it helps prevent the formation of porosity in the casting, contributing to the overall quality of the final part.
Flexibility in Design: Sow molds offer significant design flexibility, allowing for the production of complex geometries, undercuts, and specialty features. The sand can be packed into virtually any desired shape, enabling the creation of intricate and customized components.
Quick and Inexpensive Production: In comparison to investment molds that utilize a ceramic slurry, sow molds are relatively quick and cost-effective to produce. Additionally, the pattern used in sow molds can be reused multiple times to facilitate production runs of identical parts.
Practicality for Small Production Quantities: While not as precise as investment molds, sow molds provide a practical option for small production quantities and rapid prototyping. They serve as a viable solution for efficiently creating customized components and conducting initial production runs.
Sow Molds - Types and Application of Aluminium Ingots
Sure we see aluminium or products made of aluminium around us in our daily lives, but little do we know about the value chain of the metal. So, this is the space today to get acquainted with aluminium, talking of which ingot is the pure form of metal cast into a shape suitable for further processing. Aluminium ingots are heated past its melting point and cast into a bar or block using a mold chill method.
Molds are available in different shapes and sizes, lending ingots a variety of appearances.
Now when we know what aluminium ingot is, let us learn how they are made. In the cast house, crucibles of molten aluminium empty their silvery liquid either directly into molds or into a holding furnace where the metal is kept molten at temperatures between 1200 and 1500 degrees Fahrenheit. Then 400kA electrical currents are passed through the mixture to break the bond between the aluminium and oxygen. The result is 99.8% pure aluminium.
The process of casting aluminium ingots takes place through majorly two routes - either from alumina through primary aluminium or the fusion and refining of aluminium scrap. Ingots obtained through the first type of process are called primary ingots and the second type is called secondary ingots. Depending on the purity of ingots, they can also be pure or alloy ingots.
Types of aluminium ingots
Aluminium ingots are produced through the smelting process. Various grades of ingots are produced which are used for the production of castings in the auto industry as well as electrical applications. Ingots of various dimensions come with a maximum purity of 99.7%. Ingots are the material that is cast into a shape suitable for further processing. Ingots usually require a second procedure of shapings, such as cold/hot working, cutting, or milling to produce a useful final product. Aluminium Ingots are re-melted and further processed into a large number of products for various downstream applications.
Primary aluminium ingots – these are ingots of the unalloyed or alloyed aluminium cast from primary aluminium.
Secondary aluminium ingots are those obtained by recycling scrap.
Remelt ingots are those suitable for remelting. Those include large ingots called "sows” (~ 500 kg) and small ingots called "pigs" (less than 25 kg).
Extrusion ingots are intended and suitable for extruding, typically of solid circular cross-section, sometimes with a central hollow or a flattened cross-section.
T-Ingots are shaped in tri-lock shapes and designed for efficient and secure handling, are used across the construction industry, transportation, electrical goods to household appliances, T- ingots are re-melted to produce a wide variety of end products that cover the entire spectrum of aluminium applications.
A large proportion of aluminium ingots (in particular for sheet and extrusion applications) are cast by the semi-continuous, vertical direct-chill casting process (DC Casting), where water is directly sprayed onto a solidifying ingot installed on a descending platen.
Application of Aluminium Ingots
Aluminium ingots can be used in different sectors, including automotive, household appliances, lighting, construction, mechanics and household goods. The ingots are sent to other processes or flattened into thin sheets, which are then used to make new cans. Aluminium is becoming a favourite with architects and builders opening up a potential for increasing the use of metal in the construction industry.
Likewise, the use of metal is increasing in the auto sector with an increasing need for lightweight automobiles across the world.
Ingot molds come in various shapes and sizes and are typically made of durable materials such as Cast Iron, Ductile Iron, Steel or Aluminum. They are designed to shape molten metals such as Zinc, Copper, Aluminum or Lead into specific forms for future processing or storage. The molds might range in size from small handheld molds used for smaller amounts of metal to larger molds sometimes referred to as sow molds holding several thousand pounds of metal.
An ingot is a solid block of metal that's typically rectangular, square, or round in shape. It is produced by pouring molten metal into an ingot or sow mold and allowing it to cool and solidify. Once solidified, the ingot or sow is removed from the mold and can be further processed; such as by rolling, forging, cutting, or remelting to create various metal products.
Ingots are commonly used in the metalworking industry as raw material for manufacturing other metal items or for storage and transportation of metal in a more manageable form.
Advantages:
- Easy to use
- Low maintenance
- Friendly weldability
- Cost Effective
- Increased yields
- Multiple cycle use
For T-type ingot sow mold material selection: according to different production application requirements, you can choose different materials, such as ductile iron, cast steel, or alloy steel. The choice of material affects the strength, wear resistance and corrosion resistance of the sow molds.
Adopt ASTM A27 Grade 65-35 material grade, it makes T-type ingot sow mold more strong and durable, and is also suitable for some demanding engineering applications.
The applicability of sand casting process to manufacture sow mold is relatively strong, suitable for a variety of materials and specifications, and the production cycle is short.
The surface treatment of T-type ingot sow mold is an important link to improve its corrosion resistance, oxidation resistance and beauty. Usually polishing, chrome plating, spraying and other methods are used for surface treatment to increase the lifespan and market competitiveness of sow molds.
Specification
|
|
Inside mold dimensions in millimeter |
Approx. Weight (lbs) |
|||||
|
Width |
Length |
Height |
Width |
Length |
Height |
||
|
1200lb low profile |
1130 |
1485 |
290 |
1048 |
1378 |
239 |
1800 |
|
1200lb low profile w/fork pockets |
1130 |
1485 |
308 |
1048 |
1378 |
239 |
2000 |
|
1200lb high profile |
1016 |
1016 |
462 |
915 |
915 |
411 |
1630 |
|
1200lb high profile w/fork pockets |
1016 |
1016 |
475 |
915 |
915 |
411 |
1750 |
|
1500lb high profile |
1229 |
1411 |
349 |
1129 |
1310 |
299 |
2100 |
|
1500lb high profile w/fork pockets |
1229 |
1411 |
374 |
1129 |
1310 |
299 |
2400 |
|
2000lb high profile |
1254 |
1445 |
403 |
1152 |
1340 |
353 |
2400 |
|
2000lb high profile w/fork pockets |
1254 |
1445 |
429 |
1152 |
1340 |
353 |
2595 |
Whether small ingots or large sows, the efficient drying and preheating of molds is essential for workplace safety and productivity. The process is also a significant source of energy consumption and CO2 emissions – unless you switch to electric heating.
One of the most important factors in mold preheating and drying processes is consistency and repeatability. Any water vapor left behind is a significant safety risk if it meets molten aluminum, while preheating is essential for minimizing the formation of cracks in cast iron made molds.
Compared to traditional gas heaters, electrical heaters can offer more accurate temperature control, dryer and faster preheating.
Compared to traditional gas heaters, electrical heaters can offer more accurate temperature control, dryer and faster preheating. And for aluminum producers, this means a more efficient and consistent process.
Better thermal efficiency. The thermal efficiency of electric heating can be as high as 80-90 percent (compared to 15-30 percent for gas heaters).
Precise temperature control. With better and more accurate temperature control, aluminum producers can ensure a more consistent process with the same results every time.
No emissions. Switching to electric heating removes all harmful emissions, including CO2, which not only reduces a plant's carbon footprint but also contributes to a cleaner, quieter work environment.
Our Factory
Xian Huan-Tai Technology and Development Co.,Ltd was formed in 1995 to supply Aluminum dross press and steel & iron castings to the aluminum industries; Also supply mechanical products（parts) to the automotive industry, railways, oil exploration, mining, and construction for more than 27 years. Our dross press was designed by a guru in the aluminum industry for more than 40 years of experience, who has more than 250 sets of dross press installation experience. Our dross pan, drain pan, skim pot, slag bin, slag pan, sow molds, and ingot molds are made of durable castings, the material is proprietary steel.
FAQ
We're known as one of the most professional sow molds manufacturers and suppliers in China. Please rest assured to wholesale high quality sow molds for sale here from our factory. Good service and competitive price are available.
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