The power of green sand for producing steel castings

Many types of steel castings have been produced successfully in green sand for many years. They use a variety of different steel alloys, ranging from plain cast steel to highly wear-resistant alloys.

Today, more and more steel foundries are considering automated green sand moulding to increase their production efficiency, flexibility and quality.

Flexible and high quality yet affordable, DISA MATCH matchplate lines are very popular with ambitious foundries producing short and medium series. Depending on the casting geometry and production volumes, both horizontal and vertical green sand moulding lines may be suitable.

Whether you want 100 or fewer moulds per hour or maximum DISAMATIC speeds, DISA has the right equipment for your foundry.

Advantages of using green sand for steel castings

• Efficient, flexible solutions from well under 100 right up to 555 moulds per hour
• Unbeatable mould quality
• Fast, easy pattern changes takes less than two minutes, perfect for short runs
• Constant sand/metal ratio due to flaskless moulding
• Robust and simple equipment designs use the minimum of moving parts for less maintenance and unbeatable uptime
• Simple and proven core setting gives efficient, low cost, short-run production of hollow parts
• Extensive automation means only a very small workforce is needed
• Low cost patterns with many material options depending on application
• Pattern lifetime can be very high. Steel patterns can produce hundreds of thousands of moulds
• Normally only one set of pattern plates is needed, even for high production volumes
• Long service life and single set of production patterns delivers low pattern maintenance
• Short lead times from CAD file to the first prototype and to start of series production
• Changes to runners and feeders are easy, fast and cheap to make


Many foundries would profit from switching their steel castings to a green sand process. Not all steel castings can be feasibly produced in green sand but the advantages above mean that many already are.