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Permanent mold casting
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Permanent mold casting
Permanent mold casting is a metal casting process that employs reusable molds ("permanent molds"), usually made from metal. The most common process uses gravity to fill the mold, however gas pressure or a vacuum are also used. A variation on the typical gravity casting process, called slush casting, produces hollow castings. Common casting metals are aluminium, magnesium, and copper alloys. Other materials include tin, zinc, and lead alloys and iron and steel are also cast in graphite molds.
Typical products are components such as gears, splines, wheels, gear housings, pipe fittings, fuel injection housings, and automotive engine pistons.
There are four main types of permanent mold casting: gravity, slush, low-pressure, and vacuum.
The gravity process begins by preheating the mold to 150–200 °C (302–392 °F). to ease the flow and reduce thermal damage to the casting. The mold cavity is then coated with a refractory material or a mold wash, which prevents the casting from sticking to the mold and prolongs the mold life. Any sand or metal cores are then installed and the mold is clamped shut. Molten metal is then poured into the mold. Soon after solidification the mold is opened and the casting removed to reduce chances of hot tears. The process is then started all over again, but preheating is not required because the heat from the previous casting is adequate and the refractory coating should last several castings. Because this process is usually carried out on large production run work-pieces automated equipment is used to coat the mold, pour the metal, and remove the casting.
The metal is poured at the lowest practical temperature in order to minimize cracks and porosity. The pouring temperature can range greatly depending on the casting material; for instance zinc alloys are poured at approximately 370 °C (698 °F), while Gray iron is poured at approximately 1,370 °C (2,500 °F).
Molds for the casting process consist of two halves. Casting molds are usually formed from gray cast iron because it has about the best thermal fatigue resistance, but other materials include steel, bronze, and graphite. These metals are chosen because of their resistance to erosion and thermal fatigue. They are usually not very complex because the mold offers no collapsibility to compensate for shrinkage. Instead the mold is opened as soon as the casting is solidified, which prevents hot tears. Cores can be used and are usually made from sand or metal.
As stated above, the mold is heated prior to the first casting cycle and then used continuously in order to maintain as uniform a temperature as possible during the cycles. This decreases thermal fatigue, facilitates metal flow, and helps control the cooling rate of the casting metal.
Venting usually occurs through the slight crack between the two mold halves, but if this is not enough then very small vent holes are used. They are small enough to let the air escape but not the molten metal. A riser must also be included to compensate for shrinkage. This usually limits the yield to less than 60%.
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Permanent mold casting AI simulator
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Permanent mold casting
Permanent mold casting is a metal casting process that employs reusable molds ("permanent molds"), usually made from metal. The most common process uses gravity to fill the mold, however gas pressure or a vacuum are also used. A variation on the typical gravity casting process, called slush casting, produces hollow castings. Common casting metals are aluminium, magnesium, and copper alloys. Other materials include tin, zinc, and lead alloys and iron and steel are also cast in graphite molds.
Typical products are components such as gears, splines, wheels, gear housings, pipe fittings, fuel injection housings, and automotive engine pistons.
There are four main types of permanent mold casting: gravity, slush, low-pressure, and vacuum.
The gravity process begins by preheating the mold to 150–200 °C (302–392 °F). to ease the flow and reduce thermal damage to the casting. The mold cavity is then coated with a refractory material or a mold wash, which prevents the casting from sticking to the mold and prolongs the mold life. Any sand or metal cores are then installed and the mold is clamped shut. Molten metal is then poured into the mold. Soon after solidification the mold is opened and the casting removed to reduce chances of hot tears. The process is then started all over again, but preheating is not required because the heat from the previous casting is adequate and the refractory coating should last several castings. Because this process is usually carried out on large production run work-pieces automated equipment is used to coat the mold, pour the metal, and remove the casting.
The metal is poured at the lowest practical temperature in order to minimize cracks and porosity. The pouring temperature can range greatly depending on the casting material; for instance zinc alloys are poured at approximately 370 °C (698 °F), while Gray iron is poured at approximately 1,370 °C (2,500 °F).
Molds for the casting process consist of two halves. Casting molds are usually formed from gray cast iron because it has about the best thermal fatigue resistance, but other materials include steel, bronze, and graphite. These metals are chosen because of their resistance to erosion and thermal fatigue. They are usually not very complex because the mold offers no collapsibility to compensate for shrinkage. Instead the mold is opened as soon as the casting is solidified, which prevents hot tears. Cores can be used and are usually made from sand or metal.
As stated above, the mold is heated prior to the first casting cycle and then used continuously in order to maintain as uniform a temperature as possible during the cycles. This decreases thermal fatigue, facilitates metal flow, and helps control the cooling rate of the casting metal.
Venting usually occurs through the slight crack between the two mold halves, but if this is not enough then very small vent holes are used. They are small enough to let the air escape but not the molten metal. A riser must also be included to compensate for shrinkage. This usually limits the yield to less than 60%.