Permanent Mold Casting
CYCO offers precise casting services with advanced technology and superior workmanship. Whether you need complex and high-precision parts or mass production, we can meet your needs.
Overview of Permanent Mold Casting
Permanent Mold Casting (PMC) is the process of transferring molten metal into a metal mold with the help of gravity and ensuring that the metal solidifies in the mold. The molds are usually made of metallic materials such as iron, steel, aluminum or copper. These materials have excellent thermal stability and wear resistance, are able to withstand the impact of high-temperature molten metal, and can effectively transfer heat to promote rapid cooling and uniform solidification of the casting. If a sand or plaster core is used in permanent mold casting, it is called semi-permanent mold casting.
Processes of Permanent Mold Casting
1. Mold preparation: Design metal molds according to the shape, size and performance requirements of the required castings. The mold usually includes two parts: the fixed mold and the moving mold, which form a closed cavity when the mold is closed, and the shape of the cavity is the same as the final casting.
2. Coating: A special coating, usually a heat-resistant coating, is applied to the surface of the mold. This helps improve the flow of the metal and reduces adhesion to the mold surface.
3. Preheating: To ensure that the metal is fluid enough to fill the shape of the mold when it is poured, the metal mold is preheated to the proper temperature. In addition, preheating reduces the temperature difference between the mold and the molten metal to prevent excessive thermal stresses and cracks inside the casting.
4. Pouring: Liquid metal is injected into the preheated metal mold, and the pouring system can provide space for venting. Pouring can be done by gravity, pressure or vacuum to ensure that the metal fills the entire mold chamber.
5. Cooling: Once the metal has filled the mold and achieved the desired shape, the mold begins to cool. The rate and manner of cooling may affect the microstructure and properties of the final product.
6. Solidification: The casting gradually solidifies and forms a solid structure inside the cavity that is identical to the shape of the cavity. The cooling process contributes to the formation of a dense, uniform internal organization and improves the mechanical properties of the casting.
7. Holding: Keep the mold closed until the casting is completely cooled and has a certain strength so that the casting continues to cool slowly inside the cavity, which helps to reduce thermal stresses and distortion.
8. Demolding: Separate the mold after the metal has cooled completely. This reveals the molded metal part, but careful separation of the mold is required before this to prevent damage to the part or mold.
9. Post-processing: After the mold is removed, the casting is cleaned and machined, including deburring, resizing, and surface preparation. After use, metal molds may need to be cleaned, polished and repaired to maintain their accuracy and service life.
Available Metals for Parts
- Aluminum alloys
- Copper alloys
- Zinc alloys
- Magnesium alloys
- Titanium alloys
Available Metals for Molds
- Tool steel
- Alloy Steel
- Copper alloys
- Cast iron
- Cemented carbide
- Cobalt-based alloys
- Nickel-based alloys
- Titanium alloys
- Ceramics
- Steel alloys
Benefits of Permanent Mold Casting
High precision
High dimensional accuracy and low surface roughness can preserve the details and high-precision features of the parts, meeting the needs of applications with high requirements for precision and quality.
Excellent mechanical properties
Due to the high thermal conductivity of the metal mold, the casting cools quickly and has a dense internal organization, resulting in high strength, hardness, wear resistance and corrosion resistance.
Reusability
Molds can be reused thousands or even tens of thousands of times, which greatly reduces the production cost of individual castings and is particularly suitable for mass production.
Rapid production
Despite the long initial mold making time, once the mold is ready, permanent mold casting can be produced relatively quickly, enabling efficient mass production.
Good dimensional stability
The small deformation of the metal type at high temperatures is conducive to maintaining the dimensional accuracy and consistency of the castings, which reduces the scrap rate and improves production efficiency.
Adaptability
Through rational design and manufacturing, it can be used to produce small and medium-sized castings of various shapes and sizes, including thin-walled and complex structural parts.
Applications
Automotive
Engine parts, driveline components, brake system parts and other critical automotive components. This includes engine blocks, cylinder heads, crankshaft housings, etc.
Aerospace
Aircraft engine parts, turbine blades, spacecraft components and so on. Their high precision and lightweight properties make them an important manufacturing process for the aerospace industry.
Electronics
Housings, heat sinks, connectors and other critical components for electronic equipment. Aluminum is a common choice because of its good thermal conductivity and lightweight properties.
Energy
Components for energy equipment such as generator parts, turbomachinery parts and heat exchangers. This helps improve the efficiency and performance of energy equipment.
Manufacturing
Pump bodies, valve bodies, gears and mechanical parts, which provide high-precision and cost-effective solutions.
Construction
Various structural and support components such as bridge parts, building connectors and decorative elements.
Why CYCO
Professional expertise: We have an experienced and skilled team that can provide professional advice and solutions for your project.
Advanced equipment and technology: The most advanced equipment and automated production lines are used to ensure efficient and precise production. At the same time, we constantly introduce and develop new technologies to meet the needs of customers for complex shapes and high-performance parts.
Customized service: We provide a full range of customized services. From product design, mold development to mass production, we can make personalized adjustments and optimization according to your specific needs.
Fast response and delivery: We understand the importance of time in manufacturing. We are committed to providing fast response and short lead times to ensure that your project is completed within the scheduled time.
Competitive price: Through efficient production, rational use of materials and strict cost control, we offer competitive price while guaranteeing high quality.
Superior after-sales service: We not only pay attention to the production and delivery of products, but also emphasize the long-term cooperation relationship with customers. We provide perfect after-sales service, including technical support, quality tracking and problem solving to ensure your satisfaction.
FAQs
1. How to select and use mold release agents in permanent mold casting?
When selecting a mold release agent for permanent mold casting, you should consider material compatibility, temperature stability, lubrication performance, mold release effect, environmental friendliness and economy. When using, clean the mold first, and then apply evenly on the mold surface by spraying, brushing or dipping according to the type of release agent and instructions.
2. How to control the holding time in permanent mold casting?
The appropriate holding time is set according to factors such as the material, thickness and complexity of the casting. This is usually done by monitoring the temperature changes in the casting to ensure that it cools gradually and reaches adequate hardness and strength within the appropriate time, while reducing the risk of internal stresses and cracks.
3. How to reduce production costs in permanent mold casting?
The following measures can be taken to reduce the production cost of permanent mold casting:
Optimize the process: improve the casting process, reduce unnecessary steps and waste, improve production efficiency.
Material management: rational purchase and use of raw materials, reduce inventory and waste, improve material utilization.
Energy efficiency: enhance the energy efficiency of equipment, optimize the use of energy, reduce energy costs.
Mold maintenance: regular maintenance and repair of molds to extend their service life and reduce the frequency of replacement.
Quality control: strengthen quality inspection and management, reduce defects and scrap rate, reduce rework and scrap costs.
Technological innovation: adopt advanced casting technology and equipment, improve production precision and automation, reduce labor costs.