Aluminium green sand casting as an alternative to die casting
At a glance
DISA and Saint Jean Industries are combining automated green sand moulding technology with a sub-pouring process for aluminium castings. The companies regard this as a cost-effective option for applications requiring high production rates, reduced machinery requirements and lower tooling costs. At the same time, they highlight potential benefits in terms of energy and resource consumption.
A combination of green sand moulding technology and undercasting
DISA and Saint Jean Industries are presenting a combination of automated green sand moulding technology and aluminium casting with bottom pouring as an alternative to conventional aluminium die-casting. This is based on the combination of DISA’s DISAMATIC green sand moulding technology with Saint Jean Industries’ bottom pouring or EPGS process. EPGS stands for Enhanced Pressurised Gating System.
According to the two companies, this approach is designed to combine high productivity, cost-effective manufacturing and the production of high-quality aluminium castings. The focus is on an automated manufacturing process designed for industrial series production.
The collaboration builds on a long-standing partnership between DISA and Saint Jean Industries. Both companies are pooling their respective expertise to improve the efficiency, cost-effectiveness and sustainability of aluminium casting production.
Production output and cost factors
According to the partners, the process described can achieve production outputs of up to 300 moulds per hour. Actual production rates of up to 350 moulds per hour are even cited. Despite this throughput, the process is said to require significantly fewer machines and only three to four operators.
By comparison, achieving similar production volumes in die-casting typically requires more equipment and staff. DISA and Saint Jean Industries estimate that this approach can reduce part costs by 10 to 15 per cent. They also highlight significant savings in tooling costs.
The companies are thus positioning aluminium green sand casting as a cost-effective alternative for applications where high production volumes, complex component geometries and stable process conditions are required.
Applications across various industrial sectors
Saint Jean Industries and DISA do not describe green sand technology as a universal replacement for other casting processes. Rather, they see it as a cost-effective option for a wide range of applications.
Aluminium castings produced using this process are already in use in the automotive industry, agriculture, mechanical engineering, the energy sector and other industries. Particular emphasis is placed on the ability to produce complex and core-intensive components with short cycle times.
For such components, this approach may be relevant where high productivity, reduced tooling costs and the mechanical properties of high-quality aluminium castings need to be combined.
Technical characteristics of the process
A key objective of the development partnership is to combine the high production output of automated DISAMATIC green sand moulding systems with the mechanical performance of aluminium castings. The companies see this as an opportunity to offer foundries a solution for demanding applications.
According to Saint Jean Industries and DISA, the process achieves surface roughness values of 6 to 7 micrometres. These values are described as comparable to those of low-pressure die casting. The companies also highlight high process stability, good mechanical properties and improved cost-efficiency.
The partners are thus challenging the widespread perception that sand casting is fundamentally inferior to die casting in terms of productivity, surface quality or precision. Their combined experience is intended to demonstrate that automated aluminium green sand casting can be a competitive option for certain applications.
Energy and resource consumption
In addition to productivity and costs, DISA and Saint Jean Industries also highlight sustainability aspects. According to the companies, the process requires neither mould coatings nor cooling water for the moulds. Furthermore, it can reduce energy and resource consumption compared to conventional die-casting and other aluminium casting technologies.
This aspect may be relevant for manufacturers when production costs and environmental requirements are considered together. However, no specific emission figures, energy performance indicators or validated evidence of savings are provided.
Key Insights:
- DISA and Saint Jean Industries are combining DISAMATIC green sand moulding technology with the bottom-pouring or EPGS process.
- According to the partners, the process can achieve up to 300 moulds per hour; actual production rates are reported to be as high as 350 moulds per hour.
- The companies estimate that part costs can be reduced by 10 to 15 per cent, whilst moulding costs can also be cut.
- The approach is not described as a universal replacement for aluminium die-casting, but rather as a cost-effective option for specific industrial applications.
FAQ
The approach combines DISA’s DISAMATIC green sand moulding technology with Saint Jean Industries’ bottom-pouring or EPGS process for aluminium castings.
According to the partners, the process can reach a rate of up to 300 moulds per hour. The source cites actual production rates of up to 350 moulds per hour.
No. DISA and Saint Jean Industries do not describe green sand technology as a universal substitute for other casting processes, but rather as a cost-effective option for a wide range of applications.
The source states that the process requires neither mould coatings nor cooling water for the moulds, and can reduce energy and resource consumption compared with conventional die-casting and other aluminium casting technologies.