Molds

Mold casting, a fixed part of the metal processing process, is used to produce precision-forged blanks, slabs for sheet metal products, as well as profiles for wire and bar products. The process involves pouring molten metal into a specialized casting form – the mold.

This method allows metals to be cast into predefined shapes, with the mold being an economical manufacturing option that can be reused up to 100,000 times to ensure efficient and cost-effective production cycles.

Construction and Material of Molds

The mold itself is usually made of steel or cast iron and must meet several requirements to withstand the high temperatures and mechanical stresses during the casting process. These requirements include a high melting point, resistance to rapid temperature changes and mechanical wear, as well as minimal thermal expansion.

To ensure the longevity of the molds and facilitate good heat dissipation, a layer of graphite and quartz flour, known as "coating," is often applied. This layer protects the mold from direct contact with the molten metal and supports uniform cooling of the cast.

Requirements for High-Quality Molds – An Overview

The use of high-quality, temperature-resistant steel is essential to ensure the mold's durability over numerous casting cycles. For successful use in the casting process, molds must meet several requirements that significantly influence their performance and lifespan:

• Mechanical wear resistance
• High thermal load capacity
• Stability against rapid temperature changes
• Effective heat conduction properties
• Low thermal expansion at elevated temperatures
• High mechanical strength
• Resistance to deformation under heat
• Extremely high melting point

These criteria ensure that molds retain their shape under the extreme conditions of the casting process, efficiently dissipate heat, and withstand both thermal and mechanical stress. The selection and processing of the material play a crucial role in the longevity and efficiency of molds in industrial production.

Variants of Block Casting Molds and Continuous Casting Molds

In the field of mold casting processes, two main types are distinguished: block casting molds and continuous casting molds. The former is often used in the production of large, solid components and is characterized by its simple yet robust design.

Continuous casting molds, on the other hand, often use copper plates to shape and rapidly cool the molten metal, which is particularly beneficial in the production of slabs for sheet metal production. Both types of molds contribute to the efficiency and quality of the final products, with the appropriate choice of mold being crucial for the casting result and the economic efficiency of the entire production process.

Various Metals for Mold Casting Possible

Molds are widely used in the foundry industry and must meet the requirements of various casting materials. Key to selecting the mold material is the difference in melting points between the mold and the casting material, to minimize interactions between the mold and molten metal.

Among the most common casting materials processed in molds are steel, brass, cast iron, aluminum, zinc, and silicon brass, an alloy of copper, zinc, and silicon. Each of these materials has specific properties that play a role in casting, such as thermal conductivity, mechanical strength, and corrosion resistance.

The right choice of mold material and precise manufacturing processes ensure that cast products meet quality requirements and guarantee consistently high product quality.