| Foundry Process |
Process |
Advantages |
Alloys & Production |
| Green Sand Mold
|
Moist, bonded sand is packed
around a wood or metal pattern.
The pattern halves removed,
the mold is assembled with or without cores.
|
Almost any metal can be used,
almost no limit on size, shape
or weight of part, low cost, most
direct route from pattern to casting.
|
Ferrous, non-ferrous,
Low, medium, High volume
|
| No-Bake Mold
|
Chemically bonded sand place in mold boxes
surrounding the pattern halves. At room temperature,
the molds become rigid. Pattern halves are removed
and the mold is assembled with or without cores.
|
Minimum mold wall movement, better as-cast surfaces,
improved dimensional repeatability, less skill and man
hours required then in conventional sand molding.
|
Ferrous, Non Ferrous. Low, Medium and High Volume
|
| Resin Shell Mold
|
Resin coated sand is applied to heated metal
patterns forming shell-like mold halves. Pattern halves
are bonded together with or without cores.
|
Rapid production rate, good dimensional repeatability.
Lightweight molds may be stored almost indefinitely.
|
Ferrous, Non Ferrous. Medium and High Volume
|
| Permanent Mold
|
Mold cavities are machined into metal die blocks &
designed for repetitive use. Cores made of an expendable
material. The mold halves are clamped & molten metal is
gravity fed to the cavity (sometimes low pressure is applied).
Molds open and castings are ejected.
|
Good surface finish and grain structure. Good
dimensional accuracy. Repeated use of molds. Rapid
production rate. Low scrap loss and minimal porosity.
|
Non Ferrous. Medium and High Volume
|
| Die Casting
|
Molten metal is forced into closed, steel dies at
high velocities indicated by the application of pressure.
When the metal solidifies, the die is opened and the
casting ejected.
|
Extremely smooth surfaces, excellent dimensional
accuracy and rapid production rate.
|
Non Ferrous. Low, Medium and High Volume
|
| Plaster Mold
|
Slurry of special gypsum plaster mixed with water
and other ingredients is poured over pattern and allowed
to set. Pattern is removed and mold halves baked.
|
High dimensional accuracy, smooth surface finishes,
almost unlimited intricacy and no porosity. Primary for prototyping.
|
Non Ferrous. Low, Medium Volume
|
| Investment Casting
|
Refractory slurry is cast around (or dipped on)
a pattern formed from wax. When the slurry hardens,
the wax pattern is melted out and the mold or ceramic
shell is oven cured.
|
High dimensional accuracy, excellent surface finish,
almost unlimited intricacy. almost any metal can be cast.
No flash to be removed or parting line tolerances.
|
Ferrous, Non Ferrous. Medium and High Volume
|
| Centrifugal Mold
|
Metal or graphite mold is rotated in horizonal or
vertical plane (true centrifugal method). Molten metal
introduced into the revolving mold is thrown to the mold
walls where it is held by centrifugal force until solidified.
|
Rapid production rate, good soundness and cleanliness
of castings. Ability to produce extremely large cylindrical parts.
Existing mold for many sizes.
|
Ferrous, Non Ferrous. Low, Medium and High Volume
|
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