Optimization of Process Parameters and Additives for Improved Part Quality in Sand Casting: An Overview

The sand-casting process is predominantly used worldwide, especially in small-scale industries. It is very important for small component manufacturing and is one of the simple metal casting methods. However, the sand-casting process has some flaws, which also sometimes lead to a higher cost in some cases, especially the disadvantages like the surface finishing and the porosity add up to higher cost in the cases of complicated castings and their machining. This review investigates various research works done in and around the sand-casting process and tries to implement the parameters to obtain an appropriate final product from the sand-casting process, focusing on the intermediaries involved during the sand process casting and using them efficiently. These intermediaries may include the components used during the sand-casting process, predominantly sand, the metal used, the mold used for making the cavity, the chill used for promoting homogeneous nucleation, etc. Another focus is on decreasing the wastage of resources during the process. The discussed parameters will attempt to provide future directions to maximally control the disadvantages to some extent in the current process.