Chill casting process

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Pistons of a diesel engine. Gravity die casting, machined, piston alloy.

The shell casting method is a casting method in which a melt of a overhead sprue in a mold is poured said metallic permanent mold and the cavity fills alone due to gravity.

Casting process

  • Fall pouring
  • Gravity casting
  • Tilting crucible casting (by level shift)
  • Low pressure casting

Lintel casting

The simplest process using a permanent mold is lintel casting, which is primarily used for alloys with a low melting interval . A mostly two-part mold, the inside of which reproduces the contours of the casting, is filled with melt. After a short time, a solidification layer forms, the still liquid remainder of the melt is returned to the crucible and the casting is removed from the mold after further cooling.

When designing each mold, care must be taken to ensure that the liquid metal fills all areas of the mold before solidification begins in the thin-walled parts removed from the sprue. In order to prevent the occurrence of volume deficits and the formation of voids , it is usually necessary to either delay the solidification of certain parts of the casting by means of insulation or to accelerate it with cooling pins. In order to reproduce cavities or complex contours, casting cores, also in the form of core packages, are required, which are fixed at the corresponding points on the mold before the mold is filled. After cooling, the mold is opened and the casting is removed. The inserted cores, the binding agent of which is gasified or burnt, are removed from the casting by a vibrating device. Salt cores are also used, for the removal of which the casting is placed in water. Metallic cores are drawn with a cutting iron before the mold is opened.

Low pressure casting

One variant is the low-pressure casting process. The melt enters the mold through a riser pipe as soon as the bath level is pressurized. The technology favors dense and pore-free casting, an important area of ​​application is the production of aluminum wheels for automobiles.

Up to 100,000 castings can be made with one mold. In view of the cost of making the mold, a quantity of 10,000 pieces is considered the limit of economy.

Cast materials

Arrangement according to increasing strength and casting temperature.

advantages

  • less space required compared to sand casting
  • Full mechanization using robots possible
  • smooth surfaces through shape finishing
  • piece-dependent high casting performance
  • Low-pore and dense casting using the low-pressure casting process
  • low wall thickness

Web links

Commons : Die Casting  - Collection of images, videos and audio files