Cavity Mold

Permanent Mold Casting Process – Types, Advantages and Disadvantages

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About Permanent Mold Casting:

Permanent mold casting is a metal casting process in which metals and not sand is used as the mold material. Typically, cast iron, aluminum, copper alloys, zinc, tin and steel are used as the mold material in permanent mold casting. In this process , molds are pre-heated upto 200 degrees centigrade (392 degrees farenheit) before the metal is poured into the cavity. The metal molds heat up and expands during the pouring of hot metal and hence unlike sand castings the mold cavity does not need to be expanded but proper care must be taken to maintain the thermal balance during the casting process.

The Process:

In this form of metal casting process, metals are poured over the patterns to shape them into the required mold shapes. Unlike sand and plaster molds, permanent molds are not flexible to all types of patterns. Once the mold is set, the pattern is drawn out to reveal the coarse mold cavity. These cavities are to be machined to be made smooth. Cavity is then coated with a layer of refractory materials like clay or sodium silicate that makes the mold cavity heat resistant, allows easy ejection of the casting and increases the life of the mold. Machined gates are then attached to the mold.

For casting, the mold is first preheated and molten metal poured into the cavity and solidified. Once the metal is set, it is removed from the mold and the permanent mold is closed again to repeat the casting process. The casts take a weeks time to solidify.

Other types of permanent mold casting:

Gravity Permanent Mold Casting: It the flow of the metal into the mold using the force of gravity. Gravity pouring are of two types: static pouring where the molten metal is poured form the top and; tilted pouring where the mold is slanted and the metal is poured into the mold using a basin. Gravity permanent mold casting produces accurate casting than shell mold castings.

Low-Pressure permanent Mold Casting: In this process only very little amount of forces is used to push the metal into the mold. Low-pressure permanent mold casting process enables producing uniform castings with excellent dimensional accuracy, perfect surface finish and superior mechanical properties.

Slush Casting: Slush Casting is a special type of permanent mold casting in which molten metal is not allowed to solidify completely. After the desired wall thickness is obtained, the not yet solidified molten metal is poured out. This is useful for making hollow ornamental objects such as lamps, candlesticks, statues etc.

Applications:

Permanent mold casting process is used to cast products from iron, aluminum, magnesium, and copper based alloys. Typical permanent mold casting components includes gears, splines, wheels, gear housings, pipe fittings, fuel injection housings, and automotive engine pistons, timing gears, impellers, compressors, pump parts, marine hardware, valve bodies, aircraft parts and missile components.

Advantages:

Suitable for high volume casting ceramic
Quality of heavier casting improves with better use of tooling’s and equipment
Casted products have better tensile strength and elongation than sand castings
Mass productions can be done is a single production run, which reduces the manufacturing cost
Products have excellent mechanical properties.

Disadvantages:

High tooling cost
Short mold life; higher the pouring temperature, shorter the mold life.
Limited to low-melting-point metals

For more information on permanent mold casting, die casting, sand casting, investment casting, hollow casting and several other casting process and foundries, do visit: http://www.industrialmetalcastings.com

About the Author

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Mark Nel has lot of experience and great knowledge about casting industry, metal casting, sand casting,die casting,investment casting,metal casting process,industrial casting supplies,industrial casting process. He just want to share his exrperience and knowledge through article. Now he is associated with industrialmetalcastings.com

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