Sand casting prototyping system providing material characteristics replicating high pressure die casting

Abstract

The present disclosure provides a prototype sand casting system for producing a sand casting prototype that replicates material characteristics of a high pressure die cast part. The prototype sand casting system includes a sand casting mold, a plurality of flow gates in fluid connection with a mold cavity, a runner system, a first furnace, and a second furnace. The plurality of flow gates are configured to direct a plurality of parallel casting alloys including a first molten metal alloy and a second molten metal alloy into the mold cavity to form a casting. The runner system is fluidly coupled to the plurality of flow gates. The first and second furnaces are fluidly coupled to the runner system. The first molten metal alloy and the second molten metal alloy are parallel cast alloys.

Description

Technical Field

[0001] ] The present disclosure relates to developing sand cast prototypes, and more particularly, to developing sand cast prototypes having properties similar to high pressure die cast production parts. Background Art

[0002] High-pressure die casting is a metal casting process characterized by forcing molten metal under high pressure into a mold cavity with the predetermined shape of the casting. Modern vehicles, particularly hybrid and electric vehicles, are moving toward simpler body designs by die-casting very large, single-piece panels and components that serve as the body's load-bearing structure. These very large, single-piece castings are often referred to as large-piece castings or one-piece castings due to the large size of the die-casting machines used to make them. Large-piece castings make the vehicle body lighter and less complex to manufacture by replacing the numerous stamped panels and components required to form the vehicle body with a single-piece casting.

[0003] Aluminum-silicon-based alloys are commonly used for die casting of body parts and very large single-piece castings due to their light weight, excellent formability, mass production, and high strength. Typically, only one melt is used for each cast part.

[0004] The development of high-pressure die casting (HPDC) prototypes, especially for very large castings or one-piece castings, can be very expensive and time-consuming (often exceeding a year) when developing the mold. Prototype development for other metal mold casting processes (such as low-pressure die casting, counter-pressure casting, and semi-permanent molding) can also be affected by the high cost and time-consuming metal mold development. Due to the high cost and long lead time of metal molds, prototype development is often done using sand casting. However, due to the inherent differences between sand casting and metal mold processes (e.g., cooling rate, fill pattern, fill time, etc.), the level or distribution of mechanical properties of sand cast prototypes and production metal mold parts do not match.

[0005] Therefore, while high pressure die casting prototypes have achieved their intended purpose, there is a need for a new and improved method for prototyping high pressure die casting or other metal mold production parts that minimizes time and reduces expense. Summary of the Invention

[0006] According to several aspects of the present disclosure, a prototype sand casting system is provided for producing sand casting prototypes that replicate the material properties of high-pressure die-cast parts. The prototype sand casting system includes a sand casting mold, a plurality of ingates fluidly connected to the mold cavity, a runner system, a first furnace, and a second furnace. The sand casting mold includes a cavity having a predetermined shape of the casting. The plurality of ingates are configured to guide a plurality of parallel casting alloys including a first molten metal alloy and a second molten metal alloy into the mold cavity to form the casting. The runner system is fluidly connected to the plurality of ingates, and the first molten metal alloy is at least partially mixed with the second molten metal alloy in the runner system. The first furnace is fluidly connected to the runner system, and the first furnace provides the first molten metal alloy to the runner system. The second furnace is fluidly connected to the runner system, and the second furnace provides the second molten metal alloy to the runner system. The first molten metal alloy and the second molten metal alloy are parallel casting alloys.

[0007] According to another aspect of the present disclosure, a prototype sand casting system includes a runner system having a single runner containing a first molten metal alloy and a second molten metal alloy. The first molten metal alloy and the second molten metal alloy are mixed in the single runner.

[0008] According to another aspect of the present disclosure, the first molten metal alloy and the second molten metal alloy have different compositions.

[0009] According to another aspect of the present disclosure, a prototype sand casting system includes a runner system comprising a first runner fluidly coupling a first furnace and a mold cavity, and a second runner fluidly coupling a second furnace and the mold cavity.

[0010] According to another aspect of the present disclosure, a prototype sand casting system includes a mold cavity in which a first molten metal alloy and a second molten metal alloy are mixed.

[0011] According to another aspect of the present disclosure, a first molten metal alloy and a second molten metal alloy are determined based at least in part on a virtual casting tool simulation to replicate material properties of a high volume high pressure die cast (HPDC) production part.

[0012] According to another aspect of the present disclosure, a prototype sand casting system includes a third ingate fluidly connected to the mold cavity, the third ingate configured to direct a third molten metal alloy into the mold cavity to form a casting.

[0013] According to another aspect of the present disclosure, a prototype sand casting system includes a third furnace that provides a third molten metal alloy to the runner system.

[0014] According to another aspect of the present disclosure, a prototype sand casting system includes a third molten metal alloy that is different from the first molten metal alloy and the second molten metal alloy.

[0015] According to another aspect of the present disclosure, a prototype sand casting system includes at least one riser coupled to a mold cavity.

[0016] According to several aspects of the present disclosure, a prototype sand casting system is provided for producing sand casting prototypes that replicate the material properties of high-pressure die-cast parts. The prototype sand casting system includes a sand casting mold, a first runner system, a second runner system, a first furnace, and a second furnace. The sand casting mold includes a mold cavity having a predetermined shape of a casting. The first runner system is fluidically connected to the mold cavity, and the first runner system guides a first molten metal alloy into the mold cavity to form the casting. The second runner system is fluidically connected to the mold cavity, and the second runner system guides a second molten metal alloy into the mold cavity to form the casting. The second molten metal alloy is at least partially mixed with the first molten metal alloy in the mold cavity. The first furnace provides the first molten metal alloy to the first runner system. The second furnace provides the second molten metal alloy to the second runner system, and the first molten metal alloy and the second molten metal alloy flow into the mold cavity in parallel.

[0017] According to another aspect of the present disclosure, the first molten metal alloy and the second molten metal alloy have different compositions.

[0018] According to another aspect of the present disclosure, the first and second molten metal alloys have different compositions. The first and second molten metal alloys are determined at least in part based on a virtual casting tool to replicate material properties of high-volume high pressure die casting (HPDC) production parts.

[0019] According to another aspect of the present disclosure, a prototype sand casting system includes a third furnace that provides a third molten metal alloy to a third runner system. The third runner system is fluidly coupled to the mold cavity and provides the third molten metal alloy to the mold cavity.

[0020] According to another aspect of the present disclosure, the third molten metal alloy is different from the first molten metal alloy and the second molten metal alloy.

[0021] According to another aspect of the present disclosure, a prototype sand casting system includes at least one riser coupled to a mold cavity.

[0022] According to several aspects of the present disclosure, a method for providing a sandcast prototype that replicates the material properties of a high-pressure die casting part is provided. The method includes providing a first molten metal alloy from a first furnace to a runner system. The first molten metal alloy is determined at least in part based on a virtual casting tool to replicate the material properties of a large-scale high-pressure die casting (HPDC) production part. The method also includes providing a second molten metal alloy from a second furnace to the runner system. The second molten metal alloy is determined at least in part based on the virtual casting tool to replicate the material properties of a large-scale high-pressure die casting (HPDC) production part. The method also includes flowing the first molten metal alloy and the second molten metal alloy from the runner system to a sandcast mold, the sandcast mold including a mold cavity having a predetermined shape of the casting.

[0023] According to another aspect of the present disclosure, the first molten metal alloy and the second molten metal alloy have different compositions.

[0024] According to another aspect of the present disclosure, the method includes providing a third molten metal alloy from a third furnace to the runner system. The third molten metal alloy is determined at least in part based on the virtual casting tool to replicate material properties of a high-volume high pressure die cast (HPDC) production part.

[0025] According to another aspect of the present disclosure, the third molten metal alloy is different from the first molten metal alloy and the second molten metal alloy.

[0026] Further areas of applicability will become apparent from the description provided herein.It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

[0028] Figure 1 is an illustration of a simplified prototype sand casting system having a runner system with a single runner in accordance with the present disclosure;

[0029] Figure 2 is an illustration of a simplified prototype sand casting system having a runner system with a first runner and a second runner in accordance with the present disclosure;

[0030] Figure 3 According to the present disclosure Figure 1 and Figure 2 A top view of a prototype sand casting system is shown;

[0031] Figure 4 According to the present disclosure Figure 3 Line 4-4 shown Figure 1 and Figure 2A cross-sectional side view of a prototype sand casting system shown in ; and

[0032] Figure 5 is a flow chart illustrating a method for providing a sand casting prototype according to the present disclosure, the method using Figure 1 and Figure 2 Prototype sand casting system shown to replicate the material properties of high-pressure die castings. DETAILED DESCRIPTION

[0033] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. Illustrated embodiments are disclosed with reference to the accompanying drawings, in which like reference numerals indicate corresponding parts throughout the several figures. The drawings are not necessarily drawn to scale, and some features may be exaggerated or minimized to show details of particular features. The specific structural and functional details disclosed are not intended to be interpreted as limiting, but rather as a representative basis for teaching those skilled in the art how to practice the disclosed concepts.

[0034] The systems and methods disclosed herein use a virtual casting tool and multiple concurrently cast alloys to match the mechanical properties and distribution of sandcast prototypes throughout the mold to simulated high pressure die cast (HPDC) production parts. Typical mechanical property variations predicted in HPDC or other metal mold castings are achieved by using these multiple concurrently cast alloys in the sandcast prototypes.

[0035] Figure 1 is a diagram of a simplified prototype sand casting system 10 according to one aspect of the present disclosure. The prototype sand casting system 10 is configured to provide sandcast prototypes having mechanical properties and distributions similar to or equivalent to those of parts produced using HPDC or other metal molds. The prototype sand casting system 10 includes a sand casting mold 12, at least one ingate 14, a runner system 16, a first furnace 18, and a second furnace 20.

[0036] Figure 1 The illustrated sand casting mold 12 has an inner surface 22 defining a mold cavity 24. The mold cavity 24 is configured to contain molten metal to form a casting having a predetermined shape of the mold cavity 24. The inner surface 22 includes protruding details and cavities to define the mold cavity 24 having a predetermined shape and geometry for forming the desired contours and features of a cast component, such as for a vehicle (e.g., an engine block). These protruding details and cavities can form walls and structural elements, such as bosses and ribs (not shown). The shape of the mold cavity 24 is a negative mold of the predetermined casting shape. The sand casting mold 12 can be additively manufactured (e.g., three-dimensional (3D) printed sand cores and molds) and can include a variety of sand compositions (e.g., silica) and sand binding materials and processes.

[0037] like Figure 1As shown, a riser 26 is fluidically coupled to the mold cavity 24. The riser 26 is a reservoir coupled to the sand casting mold 12 for preventing cavities from forming within the mold due to shrinkage and for allowing gases and vapors to escape from the mold cavity 24. As molten metal flows into the mold cavity 24, once the mold cavity 24 is full, the molten metal enters the riser 26. Because the density of the molten metal is lower than that of the solid state, voids are formed in the casting due to shrinkage caused by cooling. As the molten metal solidifies and shrinks, molten metal is supplied from the riser to feed the mold cavity 24. Therefore, voids are formed in the riser 26 rather than in the casting. The location and size of each riser 26 can be manipulated in the prototype sand casting system 10 to match the porosity desired for the HPDC part. Although Figure 1 Three risers 26 are shown, but it should be understood that fewer or more risers 26 may be provided as part of the sand casting mold 12 and fluidly coupled to the mold cavity 24 .

[0038] At least one molten metal or alloy, such as a molten aluminum-silicon based alloy, is provided to the mold cavity 24. In determining the molten metal or alloy type and detailed composition, some considerations for each prototype's mechanical properties and distribution (e.g., ultimate tensile strength (UTS), yield strength (YS), elongation) and fatigue may include porosity / oxide volume fraction (porosity increases the further away from each ingate), secondary phase particle volume fraction and size, secondary dendrite arm spacing (since sand castings cool more slowly than HPDC castings, secondary dendrite arm spacing in sand castings is generally greater than that in HPDC castings), etc. In determining the molten metal alloy that affects local microstructure and defects, factors to be considered may include alloy composition (when multiple ingates are used), melt handling, gate / riser design, melt pouring temperature, local 3D printed cores, local chilling, heat treat design, multiple sand types used in the sand cores, and / or sand bonding processes. Molten metal or molten alloy may contain various elements, such as aluminum (Al), silicon (Si), iron (Fe), copper (Cu), magnesium (Mg), manganese (Mn), zinc (Zn), strontium (Sr), etc. Simulated molten metal alloys can be used for early product development, weldability, machining, mechanical property testing, and / or early product verification.

[0039] In one example, a first molten metal alloy 28 and a second molten metal alloy 30 (which are different alloys and have different metal alloying processes) are flowed into the mold cavity 24 and at least partially intermixed within the mold cavity 24. Multiple concurrently cast alloys are used to simulate HPDC casting. When using a single melt for HPDC prototype casting, the melt can have different material properties (e.g., elongation) at different locations within the mold, which can be difficult to predict. For example, in HPDC casting, material properties near the ingate are better predicted, while material properties farther away from the ingate are less accurate. This is also magnified in monolithic casting. Using different molten metal alloys within a sand casting is advantageous because each alloy behaves differently in different portions of the mold cavity 24, and the molten metal alloys within the prototype HPDC mold can be predicted. The first molten metal alloy 28 and the second molten metal alloy 30 can be disposed in different regions / zones of the mold cavity 24 to match the mechanical property predictions with those of a metal mold (e.g., an HPDC mold). Therefore, using sand casting prototypes with multiple molten metal alloys can better predict uniform quality throughout the casting.

[0040] In one example, the first molten metal alloy 28 comprises an aluminum-silicon based alloy, and the second molten metal alloy 30 is an aluminum-silicon based alloy different from the first molten metal alloy 28. In some cases, such as Figure 1 As shown, a third molten metal alloy 32 may also flow from a third furnace 34 into the mold cavity 24 and at least partially mix with the first molten metal alloy 28 and the second molten metal alloy 30 within the mold cavity 24. In some cases, two of the first molten metal alloy 28, the second molten metal alloy 30, or the third molten metal alloy 32 may be the same alloy, while the other may be a different alloy.

[0041] like Figure 1 As shown, the prototype sand casting system 10 includes at least one ingate 14 (or ingate gate). The ingate 14 is fluidly connected to the mold cavity 24 and is configured to direct molten metal alloys (e.g., a first molten metal alloy 28, a second molten metal alloy 30, and a third molten metal alloy 32) into the mold cavity 24 to form the sand cast prototype. Each ingate 14 is configured to ensure that the molten metal alloy flow rate is proportional to the volume of the mold cavity 24 for a given casting portion and to ensure that the molten metal alloy completely fills the corresponding portion of the mold cavity 24. In addition, each ingate 14 can promote mixing of multiple molten metal alloys (e.g., the first molten metal alloy 28, the second molten metal alloy 30, and the third molten metal alloy 32).

[0042] The mixing locations of the molten metal alloy (e.g., ingates 14, mold cavities 24, etc.) can be determined by the virtual casting tool to optimize sandcast material properties, such as porosity. Another mechanical property change that can be predicted is the elongation distribution throughout the sandcast prototype. Generally, the elongation distribution and degradation increase proportionally with the distance from each ingate 14. Therefore, when multiple ingates are used and the location of each ingate is optimized, less degradation occurs throughout the sandcast prototype. Figure 1 In the example shown, the prototype sand casting system 10 has a plurality of ingates including a first ingate 14A, a second ingate 14B, a third ingate 14C, and a fourth ingate 14D. In some aspects, the prototype sand casting system 10 can include additional ingates (e.g., a fifth ingate, a sixth ingate, etc.) or fewer ingates (e.g., three ingates, two ingates).

[0043] Still refer to Figure 1 The runner system 16 is at least one runner 36 (e.g., channel) fluidly connected to the at least one ingates 14. The runner system 16 facilitates the smooth flow of molten metal to the at least one ingates 14 and reduces the velocity of the molten metal, ensuring a stable flow and preventing slag from entering the mold cavity 24. Figure 1 As shown, the runner system 16 has a single runner 36 fluidly coupled to the first ingate 14A, the second ingate 14B, the third ingate 14C, and the fourth ingate 14D. When the single runner 36 is used, the first molten metal alloy 28, the second molten metal alloy 30, and the third molten metal alloy 32 (when included) are mixed in the single runner 36, thereby giving the casting a softer mechanical property difference within the mold cavity 24.

[0044] refer to Figure 2 , shows a prototype sand casting system 10 having a runner system 16 with a first runner 38 and a second runner 40. In an example having multiple runners, the prototype sand casting system 10 also includes a sand casting mold 12, a first furnace 18, and a second furnace 20. The first runner 38 fluidly couples the first furnace 18 directly to the mold cavity 24 of the sand casting mold 12 such that the first molten metal alloy 28 does not contact the second runner 40. The first runner 38 causes the first molten metal alloy 28 to flow into the mold cavity 24. The second runner 40 fluidly couples the second furnace 20 directly to the mold cavity 24 such that the second molten metal alloy 30 does not contact the first runner 38. The second runner 40 causes the second molten metal alloy 30 to flow directly into the mold cavity 24. The first runner 38 and the second runner 40 may not include Figure 1The prototype sand casting system 10 is shown with a separate ingate, or may not include an ingate at all. As the first molten metal alloy 28 and the second molten metal alloy 30 flow into the mold cavity 24, the first molten metal alloy 28 and the second molten metal alloy 30 at least partially mix while in the mold cavity 24 and replicate the material properties of the HPDC cast material within the prototype sand casting system 10 as predicted by the virtual casting tool.

[0045] Reference again Figure 1 , a first furnace 18 is fluidly coupled to the runner system 16. The first furnace 18 is configured to melt a first molten metal alloy 28 and provide the first molten metal alloy 28 to the runner system 16 and the mold cavity 24. The first furnace 18 may include, for example, an induction furnace, an electric arc furnace, a crucible furnace, etc. Additionally, the first furnace 18 may be a low-pressure furnace and configured to provide the first molten metal alloy 28 to the runner system 16 under no pressure or low pressure.

[0046] in addition, Figure 1 A second furnace 20 is shown fluidly coupled to the runner system 16. The second furnace 20 is configured to provide a second molten metal alloy 30 to the runner system 16 and the mold cavity 24. The second furnace 20 may include, for example, an induction furnace, an electric arc furnace, a crucible furnace, or the like. Figure 1 Also shown is an optional third furnace 34 that is fluidly coupled to the runner system 16 and provides a third molten metal alloy 32 to the runner system 16. In some aspects, the prototype sand casting system 10 can include additional furnaces (e.g., a fourth furnace, a fifth furnace, etc.). Furthermore, the prototype sand casting system 10 can include additional components, such as pouring devices (not shown) for pouring each molten metal alloy from a corresponding furnace.

[0047] Figure 3 yes Figure 1 and Figure 2 A top view of a prototype sand casting system 10 is shown. A first molten metal alloy 28 is shown flowing into a first portion 42 of the mold cavity 24, and a second molten metal alloy 30 is shown flowing into a second portion 44 of the mold cavity 24. The first molten metal alloy 28 and the second molten metal alloy 30 are at least partially mixed in the mold cavity 24.

[0048] Figure 4 It is along Figure 3 A cross-sectional side view of the prototype sand casting system 10 is shown along line 4-4. Figure 3 As shown, the first molten metal alloy 28 flows into the first portion 42 of the mold cavity 24 through the first ingate 14A, and the second molten metal alloy 30 flows into the second portion 44 of the mold cavity 24 through the second ingate 14B. Figure 4The view in FIG shows the first molten metal alloy 28 and the second molten metal alloy 30 mixing near the center location 46 between the first ingate 14A and the second ingate 14B. In other cases, the first molten metal alloy 28 and the second molten metal alloy 30 (and other alloys, if included) are also mixed throughout the mold cavity 24.

[0049] Figure 5 is a flow chart illustrating a method 100 for providing a sand cast prototype using Figure 1 and Figure 2 A prototype sand casting system 10 is shown to replicate the material properties of high pressure die cast parts.

[0050] Beginning at block 102, method 100 includes providing a first molten metal alloy 28 from a first furnace 18 to a runner system 16. Providing the first molten metal alloy 28 may include determining a composition of the first molten metal alloy 28. The composition of the first molten metal alloy 28 is determined at least in part based on a virtual casting tool. The virtual casting tool may include a software simulation configured to design and customize multi-scale defects and microstructures in a sandcast prototype. The virtual casting tool determines the composition of the first molten metal alloy 28 to replicate or reproduce the material properties of a high-volume, high-pressure die-cast (HPDC) production part. In an example, the virtual casting tool determines a castable product geometry, provides a sandcasting process simulation, provides a sandcasting prototype microstructure and porosity prediction, and provides a sandcasting prototype part local property prediction. The simulation and resulting predictions are then used to determine and provide the composition of the first molten metal alloy 28. Method 100 then proceeds to block 104.

[0051] Block 104 includes providing a second molten metal alloy 30 from the second furnace 20 to the runner system 16. The composition of the second molten metal alloy 30 is determined at least in part based on the virtual casting tool. Similarly, for the first molten metal alloy 28, the virtual casting tool determines the composition of the second molten metal alloy 30 to replicate the material properties of a high-volume, high-pressure die-cast (HPDC) production part based on sand casting simulation predictions. The method 100 may then proceed to block 106.

[0052] Block 106 includes the optional step of providing the third molten metal alloy 32 from the third furnace 34 to the runner system 16. When included, the composition of the third molten metal alloy 32 is determined, at least in part, based on the virtual casting tool. The virtual casting tool determines the composition of the third molten metal alloy 32 to replicate the material properties of a high-volume, high-pressure die cast (HPDC) production part. The method 100 then proceeds to block 108.

[0053] Block 108 includes flowing the first molten metal alloy 28 and the second molten metal alloy 30 from the runner system 16 into the sand casting mold 12 and the mold cavity 24. Flowing the first molten metal alloy 28 and the second molten metal alloy 30 includes pouring each molten metal alloy from the first furnace 18, the second furnace 20, and / or the third furnace 34, respectively. The virtual casting tool prediction and prototype casting steps (e.g., blocks 102, 104, 106, and / or 108) may be repeated until the mechanical properties of the sand cast prototype are similar to or equivalent to the predicted mechanical properties of the HPDC product. The method 100 then ends.

[0054] The prototype sand casting system 10 and method 100 of the present disclosure for providing sand cast prototypes have several advantages. Because the development of high pressure die casting (HPDC) prototypes can be expensive and time consuming, the prototype sand casting system 10 is advantageous and is designed to replicate the HPDC process rather than optimize for peak sand casting material properties. Using sand casting methods to develop HPDC prototypes can reduce the time and expense required because sand casting requires less time and is less expensive.

Claims

1. A prototype sand casting system for producing sand cast prototypes that replicate the material properties of high pressure die cast parts, comprising: a sand casting mold comprising a mold cavity having a predetermined shape of the casting; a plurality of ingates in fluid communication with the mold cavity, wherein the plurality of ingates are configured to direct a plurality of concurrently cast alloys including a first molten metal alloy and a second molten metal alloy into the mold cavity to form the casting; a runner system fluidly coupled to the plurality of ingates, wherein the first molten metal alloy at least partially mixes with the second molten metal alloy in the runner system; a first furnace fluidly coupled to the runner system, wherein the first furnace provides the first molten metal alloy to the runner system; and A second furnace is fluidly coupled to the runner system, wherein the second furnace provides the second molten metal alloy to the runner system, and wherein the first molten metal alloy and the second molten metal alloy are concurrently cast alloys.

2. The prototype sand casting system according to claim 1, wherein: The runner system is a single runner containing the first molten metal alloy and the second molten metal alloy, and wherein the first molten metal alloy and the second molten metal alloy are mixed in the single runner.

3. The prototype sand casting system according to claim 1, wherein: The first molten metal alloy and the second molten metal alloy have different compositions.

4. The prototype sand casting system according to claim 1, wherein: The runner system includes a first runner fluidly coupling the first oven and the mold cavity, and includes a second runner fluidly coupling the second oven and the mold cavity.

5. The prototype sand casting system according to claim 3, wherein: The first molten metal alloy and the second molten metal alloy are mixed in the mold cavity.

6. The prototype sand casting system according to claim 1, wherein: The first molten metal alloy and the second molten metal alloy are determined based at least in part on a virtual casting tool simulation to replicate material properties of a high volume high pressure die cast (HPDC) production part.

7. The prototype sand casting system of claim 1 , further comprising: A third ingate is fluidly connected to the mold cavity, the third ingate being configured to direct a third molten metal alloy into the mold cavity to form the casting.

8. The prototype sand casting system of claim 1 , further comprising: A third furnace provides a third molten metal alloy to the runner system.

9. The prototype sand casting system according to claim 8, wherein: The third molten metal alloy is different from the first molten metal alloy and the second molten metal alloy.

10. The prototype sand casting system of claim 1 , further comprising: At least one riser is coupled to the mold cavity.

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