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Metal Casting -Training Sessions

Our training courses are structured into separate training days.

This allows you to develop an understanding of the metal casting fundamentals in one day.

If you are interested in progressing to more advanced and self-directed projects, this can be explored during subsequent training days.

To attend a training session please send us an email to emails@greensand.com.au 

Introduction

Intermediate

Self-Directed

10am to 4pm

10am to 4pm

Prerequisites -

Complete introduction training session

Prerequisites -

Complete introduction & intermediate training sessions

Metal - Pewter

Metal - Aluminium

Metal – Bronze or Aluminium

Introductory Session

  • Welcome, housekeeping
  • introductions
  • Workshop induction, signing forms & paperwork
  • Discussion - What are your expectations for the sessions
  • Brief history of metal casting and metal casting processes
  • OH&S review. Safety equipment processes. Not if but when.
  • Molding sands (oil based, water based, other)
  • Handouts and course notes

Furnace Setup and Operation

  • OH&S review. Safety equipment processes. Not if but when
  • Safety check of furnace and furnace area
  • Pack metal into crucible
  • Start furnace set for Temp Degrees Celsius
  • Setup metal ingots for re-charge in preheat furnace
  • Start preheat furnace
  • Open furnace for re-charge
  • Housekeeping, review OH&S
  • Start furnace

Furnace Setup and Operation

  • OH&S review. Safety equipment processes. Not if but when.
  • Safety check of furnace and furnace area
  • Pack metal into crucible
  • Start furnace set for Temp Degrees Celsius
  • Setup metal ingots for re-charge in preheat furnace
  • Start preheat furnace
  • Open furnace for re-charge
  • Housekeeping, review OH&S
  • Start furnace

Overview of Patterns

  • Draft angles and parting lines
  • Sprues, vent holes, gates

 

Other information

  • Variables in the process. Log books and records.
  • Molding sands. Detailed information (oil based, water based, other)

Pre-casting discussion

  • Review project scope and size, material.

 

Demonstration Packing Molding Flasks

  • Packing pattern into flask with ‘green sand’
  • Pattern removal. Parting Powder.
  • Creating, sprues, vent holes, gates
  • Molding box design.
  • Packing molding boxes. Misalignment.
  • Demonstration packing sand into molding box with alphabet letter pattern

 

Lost Foam Casting

  • Limitations of the lost foam technique & Types of foam
  • Working with foam making models/patterns
  • Sprues, vent holes, gates.
  • Demonstration packing sand into molding box with foam pattern

 

 

Student Activity Packing Molding Flasks

  • Packing pattern into flask with ‘green sand’
  • Pattern removal. Parting Powder.
  • Creating, sprues, vent holes, gates
  •  

Student Activity Packing Molding Flasks

  • Packing pattern into flask with ‘green sand’
  • Pattern removal. Parting Powder.
  • Creating, sprues, vent holes, gates
  • Student can use pattern available
    • Rammer
    • Molding box

 

Student Activity Packing Molding Flasks

  • Packing pattern of your own design for your own project into flask with ‘green sand’, petrobond and/or sodium silicate

 

Metal Pour

  • Optional observation of Metal Pour

 

Metal Pour

  • Optional observation of Metal Pour

 

Metal Pour

  • Optional observation of Metal Pour

 

 

Types of patterns & Sand Cores

  • Sodium silicate sand cores and molds
  • Different types of patterns for cores.
  • Risers (Why and where)
  • Demonstration packing sand into molding box with traditional pattern.
  • Pack-up, Cleanup & Finish

 

 

Post-Metal Pour

  • Un-pack castings. Review results.
  • Cutting and polishing metal castings
  • Pack-up, Cleanup & Finish
  • 30 minutes - phone calls and emails for follow up questions after training
  • 30 minutes - phone calls and emails for follow up questions after training

Cost - $390

 

Cost - $590

Cost - $400

(Plus metal costs)

Notes:

  • During the Introduction Training Session a one-off 15-minute induction is required of facilities and workshop. Induction forms and indemnity disclaimer forms need to be signed. The induction, induction forms and indemnity disclaimer forms are only required to be done once and are valid for all following training sessions.
  • Kitchen facilities available (fridge, microwave, toaster) and tea, coffee and milk provided.
  • All materials, equipment and personal protective equipment (PPE) are included.
  • All metal and metal castings included for the Introduction and Intermediate Training Sessions.
  • 10% Discount on all products purchased.