Foundry Sand · Specialty Aggregates · Investment Casting Materials
Foundry Sand for Molding, Core Making and Investment Casting
Carpenter Brothers, Inc. supplies silica sand and specialty foundry aggregates for molds, cores, shell molding, and investment casting. Available products include silica, zircon, chromite, olivine, staurolite, ceramic foundry sand, coated shell sand, and refractory flours.
- Ferrous and nonferrous applications
- Multiple grain sizes and aggregate types
- Molding and core-making products
- Investment casting materials
Product Overview
Foundry Sands and Aggregates for Metal Casting
Foundry sand must withstand molten metal, maintain mold and core geometry, allow gases to escape, and provide the desired casting surface.
The right aggregate depends on the alloy, binder system, pouring temperature, casting geometry, and production process.
Silica sand is the most widely used aggregate in Carpenter Brothers’ offering. Different grain sizes and specialty blends allow foundries to balance permeability, mold strength, binder requirements, shakeout, and surface finish.
For applications involving higher temperatures, penetration, burn-in, or dimensional stability, Carpenter Brothers also supplies zircon, chromite, olivine, staurolite, and ceramic foundry sands.
Core-specific sands, refractory flours, and investment casting aggregates are also available.
Sand Performance
How Foundry Sand Affects Molds, Cores and Castings
Grain size, shape, distribution, chemistry, and thermal properties can influence mold performance and casting results. Coarser sands generally support permeability, while finer sands may help produce a smoother casting surface.
Specialty aggregates can provide different levels of thermal expansion, heat transfer, refractoriness, and resistance to molten metal penetration. Sand selection should consider the complete molding or core-making system rather than any single property.
Permeability and Mold Performance
Controlled grain size and distribution help gases move through the mold while supporting the required strength of the mold or core.
Surface Finish and Thermal Stability
Zircon, chromite, ceramic, and other specialty sands may be considered when added dimensional stability, penetration resistance, or surface-finish support is required.
Foundry Sand Types
Foundry Sand Products Supplied by Carpenter Brothers
Carpenter Brothers supplies silica sand, high-temperature specialty sands, alternative ceramic aggregates, and materials for core making and investment casting.
Silica Sand
Silica sand is available in multiple grain sizes for green sand molding, chemically bonded molds, cores, and other foundry processes.
High-Temperature Specialty Sands
Zircon and chromite sands are available for demanding iron, steel, and other high-temperature applications.
Alternative and Ceramic Aggregates
Olivine, Biasill staurolite, SphereOx Ceramic Foundry Sand®, Zircore, and Kyasill provide additional aggregate options.
Core and Investment Casting Materials
Carpenter Brothers supplies coated shell sands, fused silica, zircon flour, ceramic flour, and investment casting backing materials.
Silica Foundry Sand
Silica Sand for Molding and Core Making
Silica sand remains the workhorse of the metal casting industry because it is available in numerous grain sizes and can be used with many molding and core-making processes.
Round and sub-round grains can support flowability, compaction, permeability, binder performance, and reclamation.
Coarser silica sands are commonly used when permeability is a primary concern. Finer sands may be selected when a smoother mold face and casting surface are required.
Foundries use controlled blends to balance permeability, strength, binder demand, and surface finish.
Carpenter Brothers supplies silica foundry sand in different grain finenesses and delivery quantities. The appropriate grade should be selected according to the alloy, binder system, mold or core design, and operating conditions.
Ask About Silica Sand
Specialty Foundry Sands
Aggregates for Demanding Casting Applications
Specialty aggregates provide options for foundries that require different thermal expansion, heat-transfer, penetration-resistance, dimensional-stability, or binder-performance characteristics.
Zircon Sand
Zircon sand is used for molding, core making, facing applications, and as a replacement to metal chills.
Its low thermal expansion and resistance to wetting by molten metal can help support dimensional stability, surface quality, and resistance to penetration or burn-in.
Chromite Sand
Chromite sand has high thermal conductivity, producing a chilling effect during casting.
It is commonly considered for steel, iron, and other high-temperature applications requiring penetration resistance and controlled solidification.
Olivine Sand
Olivine is used in nonferrous and manganese steel casting applications. Its thermal properties and resistance to wetting by molten metal make it suitable for selected molds, cores, and facing-sand applications.
Carpenter Brothers has a domestic source of olivine and also imports material from Norway. Preparation and addition methods should be evaluated through foundry testing, especially when using virgin olivine as facing sand.
Ceramic and Alternative Sands
SphereOx Ceramic Foundry Sand®, FineOx Ceramic Foundry Sand®, Biasill staurolite, Zircore, and Kyasill provide additional options for foundries evaluating alternative grain shapes, thermal properties, densities, and binder requirements.
Core and Investment Casting
Sands and Flours for Specialized Processes
Carpenter Brothers supplies resin-coated shell sands produced with silica, olivine, chromite, zircon, and Zircore base materials.
Formulations can vary by grain fineness, resin percentage, additives, and release-agent package.
Core-sand selection can influence flowability, cure behavior, strength, casting surface, knockout, and reclamation.
Foundries should provide information about their alloys poured, binder system, core-making equipment, geometry, and process conditions when requesting a recommendation.
For investment casting, Carpenter Brothers supplies zircon flour, ceramic flour, stucco aggregates, fumed silica, and low- or intermediate-density backing materials.
These products are used during various stages of investment refractory shell production.
Ask About Core and Investment Casting Materials
Product Selection
Matching Foundry Sand to Your Process
Foundry sand should be selected based on the entire casting process, including the metal, pouring temperature, mold or core-making system, binder chemistry, casting geometry, and required casting results.
Grain fineness, permeability, thermal performance, surface-finish requirements, penetration concerns, shakeout, and reclamation goals should all be evaluated before final selection.
Final selection should be confirmed through foundry testing under actual operating conditions.
Talk With a Foundry Sand SpecialistSelection Considerations
Information Needed to Evaluate Foundry Sand
Reviewing the complete molding, core-making, or investment casting process helps identify aggregates and grain sizes for foundry testing.
Metal and Temperature
Identify the metal or alloy being poured, pouring temperature, casting size, and operating conditions.
Molding and Binder System
Provide the mold or core-making process, binder and catalyst system, core equipment, and curing conditions.
Sand Performance
Consider grain fineness and distribution, permeability requirements, binder demand, thermal properties, and mold strength.
Casting Results
Review casting geometry, surface-finish requirements, penetration or burn-in concerns, shakeout performance, and reclamation goals.
Available Materials
Sand, Aggregate and Refractory Flour Options
Carpenter Brothers supplies silica sand and specialty aggregates for green sand molding, chemically bonded molds, core making, shell molding, facing-sand applications, and investment casting.
Available materials include silica, zircon, chromite, olivine, Biasill staurolite, SphereOx Ceramic Foundry Sand®, FineOx Ceramic Foundry Sand®, Zircore, Kyasill, fused silica, coated shell sands, zircon flour, ceramic flour, stucco aggregates, fumed silica, and backing materials.
Product availability, grain size, formulation, packaging, and delivery quantities should be reviewed with a Carpenter Brothers technical sales representative.
Technical Support
A Foundry Sand Supplier With Industry Experience
Carpenter Brothers began in 1917 by supplying natural bonded molding sand.
Today, the company supplies silica and specialty aggregates for ferrous foundries, nonferrous foundries, core-making operations, and investment casting facilities.
Our technical sales team can help customers compare aggregate types, grain sizes, binder compatibility, packaging, and delivery options.
If you do not see the exact sand, flour, or aggregate required, contact Carpenter Brothers to discuss your application.