Permanent mold casting is a process of casting metal that employs reusable, or permanent, molds. It is named chill casting too. In our factory, we have two types permanent mold casting process
The permanent mold casting process is used in a variety of applications
where a project will see mass production or duplication of the project
is necessary. Although the process is more expensive than sand casting
and high pressure die casting, it is considered to be a cost-effective
means of part replication for most major industries.
The mold of
permanent mold casting is made from steel or iron. So the mold cost is
more expensive than sand casting molds, but the surface is better than
sand casting. But the mold of permanent mold casting is more cheaper
than high pressure die casting tooling.
In most cases, permanent mold
casting is done by using a two-piece mold. These molds are usually made
from steel or iron.. The two parts of the mold fit together snugly and
have an opening at the top for the molten metal to enter. After cooling,
the two pieces of the mold are separated, and the cast metal part is
retrieved for finishing. If the structure of casting is very complex,
there are some slits on the mold. Sometimes, Foundries have to do core
tooling, install cores into mold. After casting, take out cores.
To start the process, the mold is preheated. This step removes any
moisture that might be present in the mold and keeps the molten metal
from cooling too quickly. The preheating of the permanent mold also
prevents damage to the mold as a result of thermal expansion when the
molten metal is introduced to it.
The process of permanent mold
casting employs several means of introducing molten metal to the mold.
The most common method is the use of gravity to simply pour the liquid
metal into the heated mold. This method is the least expensive method of
permanent mold casting because it requires less equipment, but it is
not suitable for situations in which the liquid metal might not reach
all areas of the mold.
In situations where the permanent mold has
fine details that must be filled with molten metal, vacuum- or
pressure-assisted introduction of the metal might be necessary. Which is
called low pressure die casting Process.
Special Features of Permanent Mold Casting process:
❖ Produce smoother cast surface finish compared to other castings
❖ Better mechanical properties
❖ Can cast thinner walls
❖ Other inserts and pins can be casted on the part
❖ Produce parts that are lighter in weight
❖ Economical and cost-effective
❖ Lessen or eradicate secondary machining operations
❖ Good dimensional accuracy
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