Metal Casting Processes

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MATA KULIAH PROSES MANUFAKTUR II
JURUSAN TEKNIK INDUSTRI ITENAS

1. Permanent Mold Casting Processes

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The economic disadvantage of any of the expendable

mold processes is that a new mold is required for

every casting.
In the permanent mold casting, the mold is reused
many times.

1.1 Permanent Mold Casting

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It uses a metal mold constructed of two section that are

designed for easy, precise opening and closing.

These mold are commonly made of steel or cast iron.
The cavity, with gating system included, is machined into the
two halves to provide accurate dimensions and good surface
finish.
Metal commonly cast in permanent mold include aluminum,
magnesium, cooper-based alloy, and cast iron.
Cast iron requires pouring temperature. 2300 to 2700 F
(1250 to 1500 C), which take a heavy toll on mold life. The
very high temperature of steel make permanent mold
unsuitable for this metal unless the mold is made of refractory
material.

1.2 Semi-permanent mold casting

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In the permanent mold casting, a core can be made

of metal, but either their shape must allow for

removal from the casting, or they must be
mechanically collapsible to permit removal.
If withdrawal of a metal core would be difficult or
impossible, sand cores can be used. The mold is
called semi-permanent mold.

1.3 Advantages, limitations, and applications of

permanent mold casting
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Advantages:

good surface finish, close dimensional control, more rapid

solidification (caused by the metal results in finer grain
structure), strong casting are produced.

Limitations:

The process is generally limited to metal of lower melting

point, simple part (because of the need to open the mold) and
the expense of the mold

Applications:

This is best suited to high-volume production and can be

automated accordingly.

1.4 Steps in permanent-mold casting

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1.5 Variation in Permanent-Mold Casting

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Slush Casting

A hollow casting is formed by inverting the mold after partial

freezing at the surface to drain out the liquid metal in center.
Solidification begins at the mold wall since they are relatively
cool and progress over time toward in the middle of the
casting.
Slush casting is used to make statues, lamp pedestals, and toy
out of low-melting-point metals.
The exterior is important, but the strength and interior
geometry of the casting are minor considerations.

1.5 Variation in Permanent-Mold Casting

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Low-pressure casting

1.5 Variation in Permanent-Mold Casting

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Vacuum permanent-mold casting

variation of low-pressure casting in which a vacuum is used to

draw the molten metal in to cavity.
The difference is that reduced air pressure from the vacuum in
the mold is used to draw the liquid metal into cavity, rather
than forcing it by positive air pressure from below.

1.6 Die Casting

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Permanent mold casting process in which the molten

metal into mold cavity under high pressure.

General configuration:

1.6 Die Casting (continue)

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There two main types of die casting machine: (I) hot

chamber and (2) cold chamber.

Hot Chamber

1.6 Die Casting (continue)

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Cold-chamber die casting machines

1.7 Centrifugal Casting

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Several casting methods in which the mold is rotated

at high speed so that centrifugal force distributed the

molten metal to the outer region of the die cavity.
The group includes (1) true centrifugal casting, (2)
semi-centrifugal casting, and (3) centrifugal casting

1.7 Centrifugal Casting (continue)

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True centrifugal casting molten metal is poured

into rotating mold to produce a tubular part.

1.7 Centrifugal Casting (continue)

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Semi-centrifugal Casting used to produce solid

casting rather than tubular parts. G factor are

obtained and the mold are designed with risers at the
center to supply the feed metal.

1.7 Centrifugal Casting (continue)

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Centrifuge Casting Design with cavities located

away from the axis of rotation so that the molten

metal poured into the mold is distributed to these
cavities by centrifugal force. Used for small part

Thank You

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