Multiple-Use-Mold

Casting Processes

Presented by: Amirhusain Momin

ID:13103171

Introduction

In expendable mold casting, a separate mold

is produced for each casting

Low production rate for expendable mold casting

If multiple-use molds are used, productivity

can increase
Most multiple-use molds are made from
metal, so most molds are limited to low
melting temperature metals and alloys

Permanent-Mold Casting

Also known as gravity die casting

Mold can be made from a variety of different
materials

Most molds are made in segments with

hinges to allow rapid and accurate closing

Gray cast iron, alloy cast iron, steel, bronze, or

graphite

Molds are preheated to improve properties

Liquid metal flows through the mold cavity by

gravity flow

Permanent Mold Casting

Process can be repeated immediately

because the mold is still warm from the
previous casting
Most frequently cast metals

Aluminum, magnesium, zinc, lead, copper, and

their alloys
If steel or iron is to be used, a graphite mold must
be used

The permanent mold casting process consists

of the following steps:

Mold preparation - First, the mold is pre-heated to around 300-500F (150260C) 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 together.
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.

Permanent Mold Casting

Advantages of Permanent-Mold
Casting

Little finish machining

Reusable molds
Good surface finish
Consistent dimensions
Directional solidification

Disadvantages of Permanent
Mold Casting

Limited to lower melting temperature alloys

High mold costs
High production runs can validate high mold costs
Mold life is strongly tied to cost

Vacuum Permanent-Mold
Casting

Atmospheric pressure in the chamber forces

the metal upward after the vacuum is drawn
Thin-walled castings can be made
Excellent surface quality
Cleaner metals than low pressure

Lower dissolved gas content

Vacuum Permanent-Mold
Casting

High Pressure Die Casting

Molten metal is forced into the mold under

high pressure
Held under high pressure during solidification
Castings can have fine sections and complex
details
Long mold life
Typical metals cast

Zinc, copper, magnesium, aluminum, and their

alloys

Advantages of Die Casting

High production rates

Good strength
Dimensional precision
Excellent surface qualities

Disadvantages of Die Casting

High initial cost.

Limited to high-fluidity metals.

Die-Casting Dies

References

<http://www.efunda.com/processes/metal_processing/permanent_m
old.cfm>
<http://www.custompartnet.com/wu/permanent-mold-casting>
Google Images

Questons!!!
Thank you!!!