Permanent Molding Process
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PERMANENT MOLDING is very much like sand casting, but no sand is used.
The sand, is replaced by the Permanent Mold Tool. This Tool becomes the cope, the drag, and the flask. In Permanent Molding there is no real impression device, the internal shape of the Permanent Mold Tool does that. The metal tool is shaped to the configuration of the part wanted. In the terms of the Sand Casting Concept, that is explained in our Main Website, this tool assembly, is the impression device or pattern.
Visualizing the Sand Casting Concept, it can be seen, that all casting processes are in many ways, just like sand casting, or green sand molding. With a bit of thought and imagination, you can always see the cope, the drag, pattern, and the flask principle of casting. The different casting and molding processes are used to achieve a desired end product, which has a special need in the market place.
In Permanent Molding, this vessel or permanent mold tool, is closed, and molten metal is poured inside. There the molten metal is allowed to cool and set up. Then the Permanent Mold type, "cope and drag " are opened up and there is the cast part.
This is one of the tremendous economic advantages of Permanent molding, the cost reduction in tooling. In Permanent Molding, just as the names states, the mold is permanent, in that it is used over and over again, unlike a sand mold, that is re-made, after each sand cast part, is produced.
Materials suited for Permanent Molding are both ferrous, and nonferrous alloys. **************
Gravity Die Casting ? Low Pressure Die Casting ?
Permanent Molding ?
Which is it ? What is the story ?
Permanent Molding, is occasionally referred to Gravity Die Casting or also, Low Pressure Die Casting.
All casting techniques, employed in Casting and Molding Processes are in many ways, just like sand casting, or green sand molding. With some thought and imagination, you can always see the cope and drag principle of casting we already discussed, and that are shown in the Sand Casting Mini-Website. http://sandcasting.bizhosting.com
The different techniques or casting and molding processes are used to achieve a desired end product, which has a special need in the market place. This special need prompted man to develop special processes.
Permanent Molding, is actually a close relative, to the Die Casting Process. In the permanent molding process, large size components can / are produced, and in lesser annual quantities, with low to no outside pressures, than the conventional USA type, High Output Die Casting we all seem to recognize.
This comes from the thoughts in the Industry, that Die Casting, as it is known is USA, is used at high pressures of 1,000 to 10,000 psi; and is looked upon like the huge automated molding machines we all have seen, producing what appears like endless mountains of zinc and or aluminum parts.
In fact permanent molding, gravity die casting, and low pressure die casting, are really cousins by the nature of their process technologies all three share.
1. W hen using Gravity Die Casting - the metal is poured manually, with no external pressures, and most metal alloys can be used.
2. When using Low Pressure Die Casting - the metal is forced into the die, and normally is just zinc, aluminum, or zinc based alloys are used.
3. When using Permanent Molding - all large size components can / are produced, and in lesser annual quantities, with low to no outside pressures, the molds and or patterns vary by the project, and are not really subordinate to the job being cast, only the restraints of the equipment holding the patterns.
Advantages of Permanent Molding, over the other processes, are that the molten metals cool more rapidly than sand, producing a sound dense casting with superior mechanical properties, high degree of uniformity, high degree of dimensional accuracy, less scrap castings, more machining secondary operations can be easily ... " cast-out " of project – reducing overall costs, a consistent quality finish.
Examples of usage would be: Permanent Molding can replace just about all sand casting applications, where the permanent mold benefits and associated cost are desired.
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Visit the Permanent Mold Foundry
Piqua Emery Foundry @ http://www.piquaemery.com
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02/18/04 11:13:11 AM