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 alloyed steel
– High alloyed 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

SAND CASTING
MATERIALS

Certifications &
Qualifications

– ISO 9001:2015
DNV

– NORSOK
Code M-650 Rev. 4 – Duplex
and Super Dupex SS

– Pumps & Valves
Framatome – KTA 1401
ASME NCA 3800

– Pressure Equipment
TUV NORD – PED 2014/68/EU
and AD-MERKBLATT W0/TRD 100

– Austenitic Stainless Steel
Lloyds Register

– Railway Industry
D8
TUV NORD – EN 15085-2

– Marine & Offshore Division
Bureau Ventas – BV Mode II Scheme ABS

– Ships
DNV – Steel Castings

– ISO 14001:2015
DNV

Parts (Examples)

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