Definition
A metal casting process in which molten metal is poured into a mold formed from packed sand. The mold is created by pressing a pattern of the desired part into damp, bonded sand to leave a cavity in the shape of the part. After the metal cools and solidifies, the sand mold is broken away to release the casting.
Plain English
A way of making metal parts by pouring melted metal into a hollow shape made of packed sand. Once the metal hardens, the sand is broken off and the finished part comes out.
Context Anchor
Seen in powerplant material and manufacturing discussions, especially when describing how certain engine cases, housings, or other metal parts are made.
Derivation
The name describes the method literally: the mold is made of sand, and the part is cast (formed by pouring liquid metal into a mold). Casting comes from an older sense of the word meaning 'to throw' or 'to shape by pouring.'
Why Pilots Care
Many engine and airframe components start life as sand castings. Knowing this helps a technician understand why some parts have a slightly rough surface texture, why porosity or casting flaws can be a concern during inspection, and why repair limits exist for cast components.
Analogy
Like making a sandcastle with a mold, except the 'mold' is packed sand with a part-shaped hollow, and you pour in molten metal instead of filling it with more sand.
Intuition Check
Sand casting does not mean the part is made of sand. The sand is only the temporary shape that holds the hot metal until it hardens.
Example Sentence 1
The engine crankcase was produced by sand casting and then machined to its final dimensions.
Example Sentence 2
Mechanics checked the sand casting for porosity before machining the new crankcase halves.