Graphite Permanent Mold Casting

If you want to learn more, please visit our website Graphite for Continuous Casting.

Your task is to solve the problem efficiently and economically by delivering solutions that meet an array of new and emerging challenges. This includes accommodating different design considerations and adhering to rigorous standards. The time between design and production is crucial for your success.

If you are looking for more details, kindly visit Mechanical Graphite Products Supplier.

At Albco Foundry, we offer a superior alternative to traditional casting techniques by using graphite permanent mold technology (GPMT) to produce net and near-shape parts in ZA-12 zinc-aluminum alloy. We were one of the first foundries in the United States to combine ZA-12 with graphite permanent mold castings. This approach provides benefits such as faster turnaround, precision quality, and reduced total costs.

Introduction

Graphite mold casting is a modern, affordable, and quick method to produce high-quality castings. It is particularly effective for aluminum alloys and special zinc-aluminum alloys like ZA-12. Graphite mold casting is a cost-effective alternative to other casting techniques, making it suitable for mass production of items like camera housings.

Process

The graphite mold casting process starts with a mixture of graphite grains, pitch, carbonaceous cement, starch, and water. This mixture is compressed around a pattern and allowed to set. Once dry, the mold is fired to form a strong structure. The mold is then assembled with sprue, cores, and gates.

The two halves of the mold are locked together, and molten metal is injected at low pressure. Some foundries feed the molten metal from the bottom using semi-automated machines. The mold remains intact during the solidification stage. Once solidified, the mold halves are separated to remove the cast, and the process is repeated. It is essential to control the fill rate, cycle time, and temperature during pouring.

Graphite is ideal for mold making due to its stability and non-corrosive properties, enabling it to retain shape with molten metal. It is also cheaper than tool steel and doesn't require heat treating. Its machinability speeds up the mold-making phase.

Graphite Mold for Continuous Casting

Graphite molds are crucial for continuous casting processes. In continuous casting, pouring and solidification happen continuously, with the product being extracted from the open end of the mold. Continuous casting molds come in vertical and horizontal types. Mold materials vary by cast metal, such as brass, red copper, aluminum, and cast iron.

For more information on classification of special graphite, feel free to contact us.

Applications

Graphite molds allow for accurate casting of railroad car wheels, eliminating the need for further machining. High-tech camera housings are perfectly cast using ZA-12 alloys and graphite molds.

Benefits of Graphite Mold Casting

• Greater dimensional accuracy at a lower cost compared to sand and investment casting.
• The mold remains undamaged and reusable, as it does not warp or corrode.
• Graphite molds can be quickly and economically machined and modified.