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The mold life is dependent on four factors: the mold material, the pouring temperature, the mold temperature, and the mold configuration. Molds made from gray cast iron can be more economical to produce but have short mold lives. On the other hand, molds made from H13 tool steel may have a mold life several times greater.
Cast iron casting. Casting is a manufacturing process in which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process.
For the production of gray iron, ductile iron and steel castings, sand casting remains the most widely used process. For aluminum castings, sand casting represents about 12% of the total tonnage by weight (surpassed only by die casting at 57%, and semi-permanent and permanent mold at 19%; based on 2006 shipments). The exact process and pattern ...
Molten metal before casting Casting iron in a sand mold. In metalworking and jewelry making, casting is a process in which a liquid metal is delivered into a mold (usually by a crucible) that contains a negative impression (i.e., a three-dimensional negative image) of the intended shape.
Cast iron is made from pig iron, which is the product of melting iron ore in a blast furnace. Cast iron can be made directly from the molten pig iron or by re-melting pig iron, [4] often along with substantial quantities of iron, steel, limestone, carbon (coke) and taking various steps to remove undesirable contaminants.
Setup and production of shell mold patterns takes weeks, after which an output of 5–50 pieces/hr-mold is attainable. [7] Common materials include cast iron, aluminum and copper alloys. [1] Aluminum and magnesium products average about 13.5 kg (30 lb) as a normal limit, but it is possible to cast items in the 45–90 kg (100–200 lb) range.
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