Permanent mold casting | Special Casting Processes | Manufacturing Processes  |
Channel: Mechpro classes
Date: 2020-07-24

In this video session we have discussed Permanent mold casting process in detail. We also have discussed the advantages, limitations and various applications of this special casting process.

#permanentmold#permanentmoldcasting#permanentmouldcastingprocess#casting
 
Permanent mould casting is a process for producing a large number of castings using a single reusable mould. The casting process simply involves pouring molten metal into a mould where it cools and solidifies. The mould is then opened, the casting removed, and the mould is reused. The mould is made from a high-temperature metallic material, such as cast iron or hot work die steel, which can withstand the repeated heating and cooling involved with large volume production.
Permanent mould casting produces metal with better dimensional tolerance, superior surface finish, and higher and more uniform mechanical properties when compared with metal solidified using sand casting, which is another popular casting process. Permanent mould castings have relatively high strength, toughness and ductility owing to the mould walls rapidly removing heat from the liquid metal. This generates a fast solidification rate which produces a fine grain structure in the cast metal.

 Only materials with lower melting temperatures can be used in the process. While cast iron parts are manufactured using this process, the high melting point of cast iron does have a negative (or ‘wearing’) effect on the mold used. Part geometry is limited with this process as the mold needs to open and close.Another disadvantage of permanent mould casting is the high cost of the reusable mould, and that the casting process is usually viable only when  high-volume production can offset the cost or it is critical that high-quality castings are produced. 

The most common application of permanent mould casting in the aerospace industry is the casting of aluminium, titanium and steel ingots, which are then processed by working operations (e.g. forging, rolling) into aerospace structural components.

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