Permanent mold casting is a metal casting process that shares similarities to both sand casting and die casting. As in sand casting, molten metal is poured into a mold which is clamped shut until the material cools and solidifies into the desired part shape. However, sand casting uses an expendable mold which is destroyed after each cycle. Permanent mold casting, like die casting, uses a metal mold (die) that is typically made from steel or cast iron and can be reused for several thousand cycles. Because the molten metal is poured into the die and not forcibly injected, permanent mold casting is often referred to as gravity die casting.
Permanent mold casting is typically used for high-volume production of small, simple metal parts with uniform wall thickness. Non-ferrous metals are typically used in this process, such as aluminum alloys, magnesium alloys, and copper alloys. However, irons and steels can also be cast using graphite molds. Common permanent mold parts include gears and gear housings, pipe fittings, and other automotive and aircraft components such as pistons, impellers and wheels.
| Typical | Feasible | |
| Shapes: | Thin-walled: Complex Solid: Cylindrical Solid: Cubic Solid: Complex |
Flat Thin-walled: Cylindrical Thin-walled: Cubic |
|---|---|---|
| Part size: | Weight: 1 lb - 20 lb | |
| Materials: |
Aluminum |
Metals Alloy Steel Carbon Steel Cast Iron Stainless Steel Lead Nickel Tin Titanium Zinc |
| Surface finish - Ra: | 125 - 250 μin | 32 - 400 μin |
| Tolerance: | ± 0.015 in. | ± 0.01 in. |
| Max wall thickness: | 0.08 - 2 in. | 0.08 - 2 in. |
| Quantity: | 1000 - 100000 Pcs | 500 - 1000000 Pcs |
| Lead time: | Months | Weeks |
| Advantages: | Can form complex shapes Good mechanical properties Many material options Low porosity Low labor cost Scrap can be recycled |
|
| Disadvantages: | High tooling cost Long lead time possible |
|
| Applications: | Engineering components, Automotive parts, Gears, wheels, housings, engine components and industrial components. | |