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Custom Permanent Mold Castings

CUSTOM PERMANENT MOLD CASTINGS

Permanent mold casting is a metal casting process that employs reusable “permanent” metal molds. It is often referred to asgravity die casting因为通常在重力诱导的压力下通常将金属倒入管芯中而不是使用强制注射。一些制造商也使用其他过程,例如在高气体压力或真空压力下浇注熔融金属。

永久模塑铸件主要用于较小到中型金属部件的高批量生产,这是具有均匀壁厚所需的。它们可以用镁,铝,铜和许多金属合金制造,并重量从1.5盎司到150磅。由于永久模具铸件仅具有适度的产生复杂细节的能力,因此最好用于结构上更简单的部件。

使用永久模具铸件在大型生产中经常产生的金属部件的实例包括:管件,缸体,气缸盖,齿轮坯料和壳体,连杆和汽车部件,如轮子,活塞和叶轮。

PROCESS OVERVIEW

Permanent mold casting uses a strong metal mold, typically one made from steel, cast iron or a dense cast iron trademarked as Meehanite. The cost of producing the mold can be significant, but since it is permanent, the mold can be reused thousands of times. This combination of long mold life and large product volumes that can be manufactured with the same mold offsets mold production costs and makes the process very economical.

永久模塑铸件通常用于成形,包括铝,镁和铜合金的非黑色金属。然而,石墨模具也可用于铸造铁,钢和一些其他金属。

金属的永久核心或砂砂的消耗芯通常在熔融材料浇注之前插入永久模具内,并夹紧模具。然后使熔融材料冷却并固化成模具内的所需部分形状以指定的温度。

打开模具后,取出部分并进行整理工作。这消除了从浇口区域中的多余铸件,并沿着模具和/或芯的部分连接在一起的地方附加了微小的缺陷和闪光。

Step-by- step process description

永久型铸造通常需要六个步骤s:

1.定制模具创建

The first step of permanent mold casting is creating a custom mold. Each component of the mold is carefully machined from individual metal blocks, making sure that they fit together precisely, and open and close easily and accurately. The mold must also include a gate area to ensure that molten materials can enter safely.

创建模具后,它可以在模具寿命到期之前使用数千次。模具寿命被定义为模具在其有用的寿命上产生的铸件的数量。该物业通常取决于若干因素,包括:模具材料,铸造材料和工作温度。

2.模具准备

Typically, before casting, the mold is preheated to between 300 degrees Fahrenheit and 500 degrees Fahrenheit. Heated molds permit smoother metal flow and reduce defects. Preheating also reduces the possibility of damage to the mold itself from hot molten metals.

A thin protective layer of clay or sodium silicate may also be applied to interior mold cavities to function as a thermal gradient and lubricant for easier removal of the cast part, and to additionally protect the mold from damage.

3. Mold assembly

Permanent casting molds typically consist of at least two parts, including the two mold sections and any cores used to form complex features. All the parts need to be closed and held together with force prior to the pouring of molten metal inside. This is normally done with the help of machinery.

4. Pouring

Molten material enters the mold from the top at a slow rate through a gate area accessed by an opening called a sprue.

5. Cooling and mold opening

Molten metal is left to slowly solidify within the mold and cool to a desired temperature. Since many metals somewhat contract in size during the cooling process, solid metal casting needs to be removed from the mold before it cools completely to prevent the mold from cracking. This is done by means of ejector pins that are built into the mold.

6. Finishing

铸造金属部件已准备好用于最终去除任何过量的金属片段。

Characteristics of permanent mold castings

Permanent mold casting produces reduced levels of trapped gas bubbles inside metal parts while the nature of the mold allows the casting to solidify quickly and with only minor shrinkage. As a result, cast products have smaller metal grain structure, greater uniformity in every part of the cast part, and superior mechanical properties.

Permanent mold castings are also characterized by a good surface finish. Defects such as traces of metal flow lines are only cosmetic in nature, rather than functional. They can be easily removed during the finishing phase of the casting process.


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