Aluminum Permanent Casting

Aluminum Permanent Casting

  • High integrity castings  
  • Dimensional accuracy  
  • High quality surface finish  
  • High strength characteristics 
  • Cost effective tooling. 
Bronze Permanent Mold

Bronze Permanent Mold

  • High integrity castings  
  • Dimensional accuracy  
  • High quality surface finish  
  • High strength characteristics 
  • Cost effective tooling. 

Tolerances:

Aluminum:  

± .015″ to 1" then add ± .002″/in.  

Add ± .010″ to ± .030″ across parting line.

Copper Base: 

± .003″ to 1/4″  

± .004″ to 1/2″  

± .005″ per inch to 3″  

± .003″ for each additional inch.

Surface Finish: 

  • Aluminum: 125-300RMS  
  • Copper Base: 125-200RMS 

Minimum Draft Requirements: 

  • Outside: 2° Min (3° desirable) 
  • Inside: 2° Min (4° desirable) 

Metals:

Aluminum, Zinc, Yellow Brasses, Silicon Brasses, Bronze, H.C. Copper, Lead and Gray Iron 

Normal Minimum Section Thickness: 

  • Aluminum: 0.100” for small areas, 0.150” for larger areas 
  • Copper Base: 0.060” 

Size Range: Ounces to 100 lbs. 

 

Permanent Mold Casting

The process utilizes a metal casting die coated with a ceramic wash in conjunction with sand or metal cores, where applicable. The mold is preheated, and metal is introduced through gravity pour or low pressure. Steel cores if present are removed shortly thereafter. After solidification, the mold is opened, and the casting ejected. The castings then enter shakeout if sand cores are present and post processing. The mold is reassembled and the cycle repeated. 

  • Advantages:

    • High integrity castings  
    • Dimensional accuracy  
    • High quality surface finish  
    • High strength characteristics 
    • Cost effective tooling. 

Vacuum Casting

This process is a variation of permanent mold casting, utilizing a steel die and sand cores enclosed in an airtight bell housing. The mold is suspended over a furnace and molten metal is drawn into the mold by vacuum pressureAfter solidification, the die is opened, and the casting ejected. By controlling the vacuum pressure, the mold fill rate can be varied as required by part design and gating requirements. This tight control of the fill rate directly influences the soundness of the casting, reducing the potential of voids, shrinks, and gas pockets in critical areas.

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