Sand Casting Services
Zastata offers high-quality sand-casting solutions, providing a cost-effective and versatile method for producing intricate metal parts. With a decade of experience, our expert team combines traditional craftsmanship with advanced technology to ensure precision, durability, and superior quality in every casting. It is possible to create a wide variety of product shapes with sand castings. The primary limitation is that flat surfaces that run perpendicular to the separating line must have draft angles. Even complex details can be produced with a variety of metal alloys if the proper patterns, tooling, molding sands, and careful foundry procedures are all used. Whether you need a single prototype or large-scale production, Zastata is your trusted partner for reliable and efficient sand-casting solutions tailored to your needs.
Our Sand Die Castig Process
This combination allows for better dimensional accuracy, improved surface finish, and enhanced mechanical properties compared to conventional sand casting methods. The process is particularly valuable for industries requiring high-strength, heat-resistant, and corrosion-resistant components, such as automotive, aerospace, oil & gas, and heavy machinery manufacturing. By integrating advanced techniques like vacuum-assisted pouring, pressure-assisted filling, and precision machining, sand die casting ensures superior quality, durability, and efficiency, making it a preferred choice for large-scale industrial applications.
- Making a Pattern
- Mould Making
- Removing the Pattern
- Poure Molten Metal
- Cool and Solidify
- Break the Mould
- Finishing
Post Production Machining Operation and Finishing process
Stainless Steel
✔ High strength and toughness
✔ Excellent corrosion and oxidation resistance
✔ Good heat and chemical resistance
✔ Suitable for high-temperature and harsh environments
Lead
✔ High tensile strength and impact resistance
✔ Excellent machinability and weldability
✔ Affordable and widely available
✔ Can be heat-treated for enhanced properties
Copper Nickel Alloy
✔ High density and malleability
✔ Excellent corrosion resistance
✔ Superior soundproofing and radiation shielding properties
✔ Low melting point, making it easy to cast
Cast Irons
✔ Superior corrosion resistance, especially in marine environments
✔ High thermal and electrical conductivity
✔ Good strength and ductility
✔ Excellent resistance to biofouling and stress corrosion
Grey Cast Irons
✔ High compressive strength and wear resistance
✔ Excellent castability and machinability
✔ Good vibration damping properties
✔ Affordable and widely used in heavy-duty applications
Normalizing
Normalizing is a heat treatment process used to refine the grain structure of metals, improve mechanical properties, and relieve internal stresses. The process involves heating the metal to a temperature above its critical transformation range (typically between 850°C and 950°C for steel) and then allowing it to cool in air. This cooling rate is slower than quenching but faster than annealing. Normalizing results in a more uniform microstructure, enhancing strength, toughness, and machinability. It is commonly applied to steel, cast iron, and alloys used in automotive, construction, and machinery manufacturing.
Annealing
Annealing is a heat treatment process that softens metal, improves ductility, and enhances machinability by reducing hardness and internal stresses. The process involves heating the metal to a specific temperature (usually between 700°C and 900°C), holding it at that temperature, and then slowly cooling it in the furnace. This slow cooling allows the metal’s structure to become more uniform and stress-free, improving formability. Annealing is widely used in steel, copper, aluminum, and brass industries for applications like sheet metal forming, wire production, and tool manufacturing.
Quenching
Quenching is a rapid cooling process that increases the hardness and strength of metals. The process involves heating the metal above its critical temperature (around 800°C – 900°C for steel) and then quickly cooling it in water, oil, or air. This rapid cooling traps the microstructure in a hardened state, significantly improving wear resistance and strength. However, quenching can introduce residual stresses, making the material brittle. It is commonly used in steel, aluminum, and titanium to manufacture cutting tools, gears, crankshafts, and high-strength structural components.
Tempering
Tempering is a post-quenching heat treatment that reduces the brittleness and internal stresses of hardened metals while retaining their strength and toughness. The process involves heating the quenched metal to a lower temperature (150°C – 700°C), depending on the desired properties, and then allowing it to cool slowly. Higher tempering temperatures result in softer but tougher materials, while lower temperatures maintain hardness with slight ductility improvements. Tempering is essential in manufacturing automobile parts, springs, cutting tools, and structural steel components to ensure durability and resistance to fractures.
Carburizing treatment process
Carburizing is a surface hardening process that enhances the wear resistance and fatigue strength of metals by infusing carbon into the surface layer. The process involves heating low-carbon steel in a carbon-rich environment (gas, solid, or liquid) at temperatures between 850°C – 950°C. After soaking, the material is quenched to lock the high-carbon surface layer in a hardened state, while the core remains tough and ductile. Carburizing is commonly used in automotive, aerospace, and industrial applications for gears, camshafts, bearings, and fasteners that require hard exteriors with tough inner structures.
Aluminium alloys
Aluminium 713, Aluminium 356,357, Aluminium535
Brass Alloys
Brass C95400, C93500, C92600, C83300, Red Brass C83600 & C89833, Etc.
High Manganese Steel
✔ Lightest structural metal (75% lighter than steel, 33% lighter than aluminum)
✔ High strength and impact resistance
✔ Excellent machinability and damping capacity
✔ Good thermal and electrical conductivity
✔ Suitable for weight-sensitive applications
Carbon Steel
Carbon steel is an iron-carbon alloy where carbon content ranges from 0.05% to 2.0%. It is one of the most widely used metals in manufacturing due to its high strength, durability, affordability, and versatility. Carbon steel can be further modified by heat treatment and alloying elements to achieve specific mechanical properties suitable for various industrial applications.
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Sand Casting
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Post-Production Machining and Finishing Process
Polishing
Polishing is a surface finishing process that enhances the smoothness and shine of a metal component. It involves the use of abrasive materials, polishing compounds, and buffing wheels to remove imperfections, scratches, and oxidation. Polishing is essential for achieving a mirror-like finish, improving corrosion resistance, and enhancing aesthetic appeal. This process is widely used in automotive, aerospace, medical, and decorative applications to give metal parts a refined and premium look.
Sanding
Sanding is a mechanical surface preparation technique used to smooth out rough surfaces, remove burrs, and prepare metal for coatings or further processing. It involves the use of abrasive sandpapers, sanding belts, or power tools to gradually refine the surface. Sanding helps in achieving a uniform texture, improving paint and coating adhesion, and eliminating minor surface defects. It is commonly used in metal fabrication, automotive refinishing, and furniture manufacturing.
Deburring
Deburring is the process of removing sharp edges, burrs, or excess material left after machining, casting, or cutting. Burrs are unwanted rough edges or ridges that can cause safety hazards, poor assembly, and reduced performance. Deburring can be done through manual filing, tumbling, brushing, or chemical processes. It is crucial in industries such as automotive, aerospace, and medical devices, where precision and smooth edges are essential for functionality and safety.
Grinding
Grinding is a precision machining process that removes material from a workpiece using abrasive grinding wheels or belts. It is used to achieve tight tolerances, smooth surfaces, and high precision in metal parts. Grinding is commonly applied in toolmaking, automotive, and aerospace industries to refine surfaces, remove excess material, and improve dimensional accuracy. It is also used for sharpening cutting tools, finishing gears, and preparing surfaces for further treatments.
Peening & shot blasting
Peening is a mechanical surface strengthening process that enhances a metal’s fatigue resistance and durability by inducing compressive stress on the surface. It is achieved through methods like hammer peening or shot peening, where small steel balls or glass beads are blasted onto the surface. This process helps to increase toughness, prevent cracking, and improve resistance to stress-induced failures. Peening is widely used in automotive, aerospace, and structural steel components to extend the lifespan of critical parts.
Fettling
Fettling is a cleaning and finishing process used in metal casting to remove excess material, such as gates, risers, flash, and sand residues, from cast components. It involves grinding, chipping, or cutting to achieve the final desired shape and smoothness of the casting. Fettling improves dimensional accuracy, surface quality, and overall performance of cast products. It is a crucial step in foundries and metal casting industries to ensure high-quality finished parts.
Painting and Powder coating
Painting and powder coating are protective and decorative finishing processes that enhance the appearance and durability of metal components. Painting involves applying liquid paint with a spray or brush, followed by curing. Powder coating, on the other hand, is a dry finishing process where a fine powder is electrostatically applied and cured under heat to form a durable, uniform coating. These coatings protect against corrosion, UV damage, and wear, making them ideal for automotive, construction, machinery, and consumer goods industries. Powder coating is preferred for its eco-friendliness, durability, and superior finish compared to traditional painting.
ISO 9001:2015
(Quality Management System)
ISO 14001:2015
(Environmental Management System)
ISO 45001:2018
(OH & SMS)
AS9100 Rev C
(Aviation, Space and Defence)
ISO13485:2016
(Medical Devices)
IATF16949:2016
(Automotive Quality Management System)
Advanced Product Quality Planning
Advanced Product Quality Planning (APQP) is a structured process used in the manufacturing industry to ensure that a product meets customer expectations and quality standards. It is a proactive approach that helps companies identify potential risks, minimize defects, and improve production efficiency before full-scale manufacturing begins. APQP is widely used in the automotive, aerospace, and industrial manufacturing sectors to ensure high-quality product development and launch.
Failure Mode Effective Analysis
Failure Mode and Effects Analysis (FMEA) is a systematic risk assessment tool used to identify potential failures in a product, process, or system and evaluate their effects. It helps organizations detect, prevent, and mitigate risks before they cause serious defects or failures. FMEA is widely used in automotive, aerospace, healthcare, and manufacturing industries to ensure product reliability and quality.
Production Part Approval Process
The Production Part Approval Process (PPAP) is a standardized procedure in the automotive and manufacturing industries that ensures suppliers meet customer requirements before starting mass production. It helps confirm that a supplier’s production process can consistently deliver high-quality parts that meet design, engineering, and safety specifications.
Statistical Process Control
Statistical Process Control (SPC) is a data-driven quality control method used in manufacturing to monitor and control production processes. It involves using statistical techniques and control charts to detect variations, identify trends, and maintain product quality. SPC helps manufacturers reduce defects, improve efficiency, and ensure process stability.
Measurement System Analysis
Measurement System Analysis (MSA) is a statistical method used to evaluate the accuracy, reliability, and consistency of a measurement system. It helps determine whether the measuring instruments and processes used in quality control are capable of providing trustworthy data. MSA is widely used in industries such as automotive, aerospace, manufacturing, and healthcare to ensure precise and repeatable measurements for decision-making.