Permanent mold casting process consists of the following steps:
Mold preparation - First, the mold is pre-heated to around 300-500° F (150-260° C) to allow better metal flow and reduce defects. Then, a ceramic coating is applied to the mold cavity surfaces to facilitate part removal and increase the mold lifetime.
Mold assembly - The mold consists of at least two parts - the two mold halves and any cores used to form complex features. Such cores are typically made from iron or steel, but expendable sand cores are sometimes used. In this step, the cores are inserted and the mold halves are clamped together.
Pouring - The molten metal is poured at a slow rate from a ladle into the mold through a sprue at the top of the mold. The metal flows through a runner system and enters the mold cavity.
Cooling - The molten metal is allowed to cool and solidify in the mold.
Mold opening - After the metal has solidified, the two mold halves are opened and the casting is removed.
Trimming - During cooling, the metal in the runner system and sprue solidify attached to the casting. This excess material is now cut away.
Applications: Gears, wheels, housings, engine components and so on.
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