Sand Castings

FERESPE, founded in 1981, focuses on the production of technical parts for high performance applications, using the following alloys:

– Duplex, super duplex and super austenitic stainless steel
– Medium and low alloy steel
– High alloy cast iron

Exports about 90% of its production to several different industrial sectors and positions itself in a small and medium series niche market.

Sand Castings uses a silica-based material to create a moulding surface. After achieving the required chemical composition, the molten metal is poured into a mould which has the desired shape cavity to cool down and solidify .

Main Characteristics of Sand Casting:

  • Larger castings
  • Good Dimensional Accuracy
  • Good Roughness Quality
  • Complex shape and near net shape design, if compared with forging or metal worked pieces

TECHNICAL PARTS

Sand Castings

High Performance applications

PRODUCTION RANGE

Minimum Thickness

7 – 8 mm

Roughness

12.5 – 25 µm

Maximum Dimension

1300x1000x800 mm

(mechanical moulding)

1300x1075x1100 mm

(hand moulding)

Maximum Weight

650 Kg

Materials

Duplex, super duplex and super austenitic stainless steels
Medium and low alloy steels
High alloy cast irons

Patternless Solutions

Surface treatment

Machining

FERESPE CAPACITY

FERESPE CAPACITY

  • 1000 tons of finished parts
  • Traditional + 3D machining
  • High frequency and compressed air
  • 4 Induction furnaces
    • 2 Furnaces 1Ton capacity
    • 1 Furnace 500Kg capacity
    • 1 Furnace 150Kg capacity
  • Mechanical moulding

    Up to 1,300 x 1,000 x 800 mm and 650 kg

  • Hand moulding

    Up to 1,300 x 1,075 x 1,100 mm and 650 kg

  • 2 sand mixers

    Capacity: 20 tons/hour

  • IRIS pattern recognition system

    Optimized process control

SAND CASTING MATERIALS

CERTIFICATES & QUALIFICATIONS

CERTIFICATES
& QUALIFICATIONS

Quality Management
ISO 9001:2015

Environmental Management
ISO 14001:2015

Railway
HPQ DB
EN 15085-2

Pressure Equipment
PED 2014/68/EU
AD-MERKBLATT W0

Valves and Pumps
KTA 1401
ASME NCA 380

NORSOK / Special Materials
Code M-650 Rev. 4
ISO 17782

Marine & Offshore – approved manufacturer
BV Marine
ABS
DNV
Lloyd’s Register

EXAMPLE PARTS

FERESPE In Action at Sand Casting Unit

FERESPE In Action at
Sand Casting Unit

Office

Production

Quality Control

Finishings

PLANT

Product Engineering

  • Modeling
    • PTC Creo 3.0
  • 3D Scanning
    • Dimensional Control
    • Reverse Engineering
  • Simulation: Filling and Solidification
    • Finite Solutions Flowcast and Solidcast
  • Pattern Making:
    • Rapid Prototyping:
      • SLA
      • SLS
      • 5-axis rapid machining – sand or composite material (subcontracted)
      • Traditional pattern makers (subcontrated)

Moulding

  • Mechanical Moulding
    • Up to 1.300 x 1.000 x 800 mm and 650kg
  • Hand Moulding

    • Up to 1.300 x 1.075 x 1.100 mm and 650kg
  • 2 Sand Mixers

    • Capacity: 20 Ton/Hour
  • IRIS Pattern Recognition System

    • Optimized process control

Melting

4 Induction Furnaces

  • 2 Furnaces Capacity: 1Ton
  • 1 Furnaces Capacity: 500Kg
  • 1 Furnaces Capacity: 150Kg

Finishings

  • Dedicated area for Stainless Steels

    • Shot-blasting, Grinding and Welding
  • Shot blasting machines

    • CM and NORMFINISH
  • Grinding Machines

    • High frequency and Compressed air
  • Heat Treatments

    • In-house heat treatments
  • Other activities, such has machining, coatings, surface chemical treatments, among others, can be subcontracted to FERESPE’s experienced partners.

Quality Control Equipment

  • Optical Emission Spectrometers
  • Destructive Testing
  • Non Destructive Testing
  • Hardness Control
  • Samples Preparation and Metallographic Analysis

Sand Castings Material List

Material List