Scribd
Upload
204 views15 pages

Permanent Mold Casting

The document discusses permanent mold casting processes. It is a metal casting method that uses reusable metal molds, typically for high volume production of small metal parts. The document outlines the process steps and limitations and advantages of the technique.

Uploaded by

Eka Rosmitalia
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
204 views15 pages

Permanent Mold Casting

The document discusses permanent mold casting processes. It is a metal casting method that uses reusable metal molds, typically for high volume production of small metal parts. The document outlines the process steps and limitations and advantages of the technique.

Uploaded by

Eka Rosmitalia
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
You are on page 1/ 15

PERMANENT

MOLD CASTING
PROCESSES
Arranged by :
1. Yohanes Essa Yubi Pratama / 13-2018-083
2. Yockeu Julyani / 13-2018-099
3. Siskia Dwifitri Amanda / 13-2018-104
4. Davin Leonardus Nabin / 13-2018-105
What is a permanent mold casting
processes ?
Permanent mold casting is a metal casting process with uses a metal mold (die) that is typically
made from steel or cast iron and can be reused for several cycles.

Permanent mold casting is typically used for high-volume production of small, simple metal parts
with uniform wall thickness. Non-ferrous metals are typically used in this process, such as
aluminum alloys, magnesium alloys, and copper alloys. However, irons and steels can also be cast
using graphite molds. Common permanent mold parts include gears and gear housings, pipe
fittings, and other automotive and aircraft components such as pistons, impellers, and wheels.
The Limitations of Casting Using Permanent
Mold Processes

The limitations of casting using the permanent mold process includes:


Only materials with lower melting temperatures can be used in the process.
While cast iron parts are manufactured using this process, the high melting point of cast iron does
have a negative (or ‘wearing’) effect on the mold used.
Part geometry is limited with this process as the mold needs to open and close.
This particular casting process becomes a less viable option when compared to sand casting in case
s where three or more sand cores are required.
Disadvantages of Casting

Other limitations and disadvantages of casting using this particular process includes:
• A high tooling cost and a long set-up time.
• The permanent mold casting process is, in general, limited to smaller castings.
• Because of the high tooling cost involved, a high production volume is needed in order to make this process and economically
viable manufacturing option.
• The higher the pouring temperature of the molten metal, the shorter the life of the mold.
• If an error occurs it is difficult to fix.
Advantages of Casting

The advantages of casting using this specific process includes:


• The main advantage of permanent mold casting is the fact that mold used in the process, can be reused.
• The process is capable of producing more complex shapes and designs than sand casting.
• The part casted has a good surface finish (as casted). The surface finish delivered here is better than that of sand casted part
s and components.
• Gravity die casting allows for a more precise control over dimensional attributes than sand casting processes are able to.
• The casting process itself is highly repeatable and is well suited for high volume production runs. The process can also be a hi
ghly automated one.
• Permanent mold casted parts have good mechanical properties, low shrinkage and a low gas porosity.
• Parts have a homogeneous grain structure and the process itself produces little scrap.
• Can be used to mass-produce
The permanent mold casting process consists of
the following steps

Mold preparation - First, the mold is pre-heated to around 300-500°F (150-260°C) to allow
better metal flow and reduce defects. Then, a ceramic coating is applied to the mold cavity
surfaces to facilitate part removal and increase the mold lifetime.
Mold assembly - The mold consists of at least two parts - the two mold halves and any cores used
to form complex features. Such cores are typically made from iron or steel, but expendable sand
cores are sometimes used. In this step, the cores are inserted and the mold halves are clamped to
gether.
Pouring - The molten metal is poured at a slow rate from a ladle into the mold through
a sprue at the top of the mold. The metal flows through a runner system and enters the
mold cavity.
Cooling - The molten metal is allowed to cool and solidify in the mold.
Mold opening - After the metal has solidified, the two mold halves are opened and the casting is removed.
Trimming - During cooling, the metal in the runner system and sprue solidify
attached to the casting. This excess material is now cut away.
Variation in Permanent-Mold Casting

Slush Casting
As seen in the conventional process, the molten metal is poured into the mold and
allowed to cool and solidify at the cavity’s surface.
When the amount of solidified material is equal to that of the desired wall thickness, the
remaining material which has not yet solidified, is poured out of the mold.
This technique is commonly used to cast hollow parts without making use of cores.

Advantage: Slush casting is used to produce hollow parts without the use of cores
The desired thickness can be achieved by pouring our the left over molten metal
A variety of exquisitely designed casting can be casted for decorative and ornamental p
urpose.
Vacum Permanent Mold Casting

Vacuum pressure is applied to fill the mold.


Much like the low pressure technique, vacuum casting allows thinner walls, finer details, and better mechanical properties.
Application : Vacuum molding process can be used to cast industrial components from both ferrous and non-ferrous metals.

Application : Casted products have high dimensional accuracy and surface finish.
The process is economical, environment friendly and clean
No moisture related defects for the castings
Provides consistent thickness for wall that give the casting an aesthetic appeal
Low cost operations.
Low Pressure Permanent Mold Casting
Instead of pouring the molten metal, the metal is forced into the mold by using low pressure air.
This technique allows the mold to remain filled, and aids in reducing shrinkage caused during the cooling process.
This technique also allows for the molding of finer details and thinner cast walls.
Some Advantages of Low Pressure Permanent Mold Castings:
Thin walled casting can be produced
Mechanical properties are increased about 5% over Permanent Mold Castings
Excellent process for creating intricate designs such as circular patterns
Increased surface finish of as-cast castings
Higher density castings
Low tooling costs
Able to produce pressure tight castings
Thank you

You might also like