Permanent Mold

Casting

General Manufacturing Processes Engr.-20.2710

Instructor - Sam Chiappone
 Permanent mold casting (PMC) is the process of transferring
molten metal to a metal mold by the gravity assistance and
ensuring that the metal solidifies in this mold. If cores made of
sand or plaster used in the PMC, method is called as semi-
PMC
 Permanent mold casting is a casting process that, as the name suggests,
involves the use of a permanent mold. Unlike with casting processes, the mold
can be reused for multiple casting applications. During permanent mold
casting, molten metal is forced into a mold cavity. As it fills the mold cavity, it
creates a new object in the same shape and size. While all permanent mold
casting processes involve filling a reusable mold with molten metal.
 There are four main types of permanent mold casting: gravity, slush, low-pressure, and
vacuum.
 Permanent molds are designed to be reused and able to withstand multiple operations.
they are created to be easily removed and be used as the mold for the next casting.
 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).
 Applications: Permanent mold casting process is used to cast products from
iron, aluminum, magnesium, and copper based alloys. Typical permanent
mold casting components include 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.
 1) Gravity Permanent Mold Casting
 Gravity permanent mold casting is an approach that uses a preheated mold.
The mold is heated to a temperature of about 300 to 400 degrees Fahrenheit,
after which it’s filled with molten metal. The use of a preheated mold allows
the molten metal to flow more easily. Gravity permanent mold casting has a
lower rate of defects because the molten metal is cable to fill the mold cavity
more effectively when compared to other permanent mold casting processes.
 2) Slush Permanent Mold Casting
 Another approach to permanent mold casting is slush. What is slush mold
casting exactly? It’s essentially a variation of permanent mold casting that’s
used to produce hollow castings. During slush permanent mold casting,
molten metal is poured into a special mold cavity. The molten metal doesn’t
completely fill the mold cavity. Rather, it fills the sides of the mold casting,
essentially creating a shell. Once the shell has formed, it’s ejected from the
mold cavity.
 #3) Low-Pressure Permanent Mold Casting
 A third approach to permanent mold casting is low pressure. Low-pressure
permanent mold casting is a casting process that uses pressurized gas to force
molten metal into a mold cavity. The gas is typically pressurized to around 3
to 10 pounds per square inch (PSI). Although it’s not a substantial amount of
pressure, it’s more than enough to force molten metal into a mold cavity. With
pressurized gas, the molten metal is able to completely fill the mold cavity
 #4) Vacuum Permanent Mold Casting
 Finally, vacuum permanent mold casting is a casting process that uses vacuum
pressure to fill a mold cavity with molten metal. It’s similar to low-pressure
permanent mold casting, with both processes using pressure to fill a mold
cavity with molten metal. Vacuum permanent mold casting, however, uses
vacuum pressure, which often results in better physical properties when
compared to its low-pressure counterpart.
PERMANENT MOLD
CASTING VS. DIE CASTING

 The major difference between the two steel die techniques is

how the metal gets into the tooling. In permanent mold casting,
metal flows into the cavity from a reservoir.
 A gate controls the speed of flow to reduce turbulence.
Typically, the die will be designed to fill from the bottom or
side with the riser at the highest point.
PERMANENT MOLD
CASTING VS. DIE CASTING

 In contrast to (gravity-fed)permanent mold casting, with die

casting, metal is forced into the cavity under pressure. This
makes it very similar to plastic injection molding. As with
permanent mold casting, once the metal solidifies, the mold
opens and the cast forms are removed.
 Molds Vs. Dies
 A mold is a hollowed-out block that is filled with a liquid
such as plastic, glass, metal, or ceramic raw material. The
liquid hardens or sets inside the mold, adopting its shape.

 Mold is the counterpart to a cast. The very molding

process uses two molds, one for each half of the object.

 Articulated molds have multiple pieces that come together

to form the complete mold, and then disassemble to
release the finished casting; they are expensive, but
necessary when the casting shape has complex contours.
• A DIE IS a block of metal with a special shape or with a pattern cut
into it that is used for shaping other pieces of metal such as coins or
for making patterns. A MOULD is a container that you pour sift liquid
or substance into which then becomes solid in the same shap as the
container e.g. when it is cooled or cooked .
• Dies and molds are both tools for shaping. Dies are used to shape
sheet metal and other metal forms. A typical application is the
making of automobile body parts. On the other hand, molds are used
in injection molding such as with melted resin or casting molten
metal.
 Molds Vs. Dies
 In Die casting, Molten metal is poured or injected into
dies and allowed to cool. The die is then removed, and
the product is ready for finishing. Die casting is a
relatively fast process, which allows for faster
production. It is not as refined as the molding process,
and die-cast objects may not be as strong as products
made with an injected mold.
Multiple Use Mold

 Advantages
 Mold is reusable
 Generally, a good surface finish is obtained
 Dimensional accuracy can be as good as +/- .003”
 Control of mold temperatures
Multiple Use Mold

 Disadvantages
 Majority of molds use low-melt alloys
 Mold costs can be high
 Mold life varies
 Temperature of alloy being poured
 Mold material
 Mold temperature
 Thermal shock
 Mold configuration
Permanent Mold Casting (Gravity)

 The tool
 Molds are machined from tool steels and can have metal
retractable cores
 The Process
 Molds are pre-heated
 Molten metal is poured into the molds and enters the mold cavity
through the gate under gravity feed. After solidification….mold is
opened and part removed
 Permanent Mold Casting

 Metals
 Aluminum, Zinc, Magnesium, Copper,and Brass Alloys
 Tolerances
 +/- .012” first inch (add .002” per inch)
 Wall section .125”
 Normal Minimum Section Thickness:
 Aluminum:.100" for small areas, up to 3/16" or more for large areas.
 Copper Base: .060"
 Ferrous: 3/16" for small areas, 1/4" normal.
 Advantages

 Generally the same as all other multiple use molds……and

mold life is about 25,000 + cycles
Disadvantages

 Some limitations in complexity of mold and fine section detail

may be limited
Pouring Process

Figure 13-19 Automatic pouring of molds on

a conveyor line. (Courtesy of Roberts Sinto
Corporation, Lansing, MI.)
Die Casting

 The Process
 Molten metal is forced into the die cavity under pressure. The
metal is kept under pressure until it solidifies. Pressure ranges are
1,500 p.s.i. to 25,000 p.s.i.
Process Steps

 Lubrication of dies
 Closing and locking of dies
 Molten metal is forced into the die cavity
 Held under pressure until it solidifies
 Die opens
 Casting is ejected
 Process Parameters

 Normal Minimum Section Thickness:

 Al: .03" Small Parts: .06" Medium Parts
 Mg: .03" Small Parts: .045" Medium Parts
 Zinc: .025" Small Parts: .040" Medium Parts
 Tolerances:
 Al and Mg ± .002"/in.
 Zinc ± .0015"/in.
 Brass ± .005"/in.
 Metals: Aluminum, Zinc, Magnesium, and Brass
 Machines

 Hot Chamber
 15 cycles per minute
 Direct transfer of molten metal into die cavity
 Used primarily with zinc and zinc alloys
 Cold Chamber
 Higher temperature alloys (aluminum and magnesium)
 Metal is melted in a separate furnace and transported to the machine
 Measured quantity of metal is forced into the mold by a hydraulic or mechanical
plunger (can be a double plunger system for productivity)
Advantages

 Fine section detail (.003”)

 Excellent dimensional accuracy (+/- .002”)
 High production rates
 Excellent surface finish
 Control of process temperatures
 Extended mold life
 Limited part defects
Disadvantages

 Part size (up to 75 lbs.)

 Limited to low melt alloys
 Initial tooling costs are high
Process Selection and Cost

 Each casting process

has advantages and
disadvantages
 Typical requirements
 Size, complexity,
dimensional precision,
surface finish, quantity, Figure 13-20 Typical unit cost of castings
comparing sand casting and die casting. Note how
rate of production the large cost of a die-casting die diminishes as it
 is spread over a larger quantity of parts.
Costs for materials (dies,
equipment, and metal)
Process Selection and Cost
Casting Defects
Casting Defects
Casting Defects