Green-sand molding systems remain the most widely employed process of their type. The basic components — silica sand, clay, and water — are easily available almost everywhere, and in consistent quality, with a narrow tolerance range of variability.

Coal dust, and other additives, are casting finish enhancers added to the basic components according to the individual foundry’s requirements. Over time metalcasters have to learn the best individual characteristics of each element to obtain the best sand mixture. Customers’ continual demands for better-quality castings, along with casting price control, have helped to create a permanent research and development process involving a partnership of foundries, raw material suppliers, and equipment manufacturers.

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