How we work
The casting process
Sa&Bar uses exclusively the no-bake process: sand molding with self-setting resins. It is the most suitable technology for the production of complex components, with articulated geometries, internal cores and high weights — up to 600 kg per single casting. It guarantees production flexibility both on prototypes and on repeated small series.
From pattern to sand mold
The pattern supplied by the client is prepared and positioned on the mechanized molding line. Sand mixed with self-setting phenolic urethane resins is poured into the flask and compacted. Within minutes the sand hardens, the mold is extracted and sent to the next stage via conveyor belts. Where the design requires it, sand cores are produced and inserted to create internal cavities.
Aluminum pouring
In parallel with molding, the melting furnaces bring the aluminum to pouring temperature. The molten metal is poured by gravity into the closed molds and left to cool on the waiting lines. Any smelting slag is separated and handled separately. Risers and gating channels re-enter the production cycle as material to be remelted.
Shake-out and sand recovery
After cooling, the molds are overturned on the shake-out machine, which breaks up the sand and frees the casting. The sand is recovered and reintroduced into the production cycle through mechanical and thermal reclamation plants. The rough casting is then sent to subsequent operations.
Casting fettling
Once shaken out, the casting is sent to fettling operations. Metal excesses — risers and flash — are removed with band saws and subsequently finished with milling machines and grinders depending on the geometry of the part. On client request, surface shot blasting is also carried out, using a rotary table machine with stainless steel shot.
Pre-delivery inspection
Every casting is inspected on the basis of the work order defined at order stage. On client request we provide heat treatment, inspection certificate and/or radioscopic examination. Sa&Bar has been ISO 9001 certified since 1998 and Lloyd's Register since 2011.
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