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Introduction to Aluminum Casting Options

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Introduction to Aluminum Casting Options Casting vs Fabrication Cumulative Cash Outflow Based on 500 Units per Year Fabricated Parts @ $175 Each, Ready to Assemble Cast/Machined Parts @ $125 Each, Ready to Assemble Casting Fabrication $100,000 $342,500 Year 5 cumulative saving $440,500 after 5 years $280,000 Year 4 $353,000 $217,500 Year 3 $265,500 $155,000 Year 2 $178,000 Tooling payback by $92,500 savings 1 year Year 1 $90,500 production $30,000 Year 0 (Tooling) $3,000 Disposable Mold Casting Methods • Sand • Green Sand • Petrobond (oil sand) • Dry Sand (chemically bonded, no-bake) • Shell Molded ( Resin sand ) • Investment ( Lost Wax ) • Ceramic Shell (Dipped in slurry and stucco) • Solid Mold (Poured into flasks) Disposable Mold Casting Methods • Plaster Mold ( Shaw Process, Split P/L mold) • -V- Process • Lost Foam Reusable Mold Casting Methods • Pressure Diecast • Conventional • Squeeze Casting • MFT Vacuum • Permanent Mold • Static • Tilt Pour • Low Pressure • Semi Solid Molding ( MAINLY AUTOMOTIVE ) • Thixotropic casting ( SSM from Billet ) • Rheocasting (billet produced at machine) Sand Casting Advantages Disadvantages Quick Turnaround – Minimum wall is 3/16” + draft required Low tooling dollars – 250-400 RMS finish Low to high volume capable – Limited definition of features and details Many vendors available – Loose tolerances often require secondary Easy to revise tooling machining. Process/Equipment is easily scalable to large parts Plaster Mold Casting Advantages Disadvantages Low Tooling Cost. – Unit prices are higher than sand Good for prototyping of diecastings and -V- Process. – Vendors typically “agile” to leadtime and Daily output limited to low quantities revisions. – Poor plating and pressure tightness due to gas porosity. Investment Casting Advantages Disadvantages Thin wall – Highest casting unit price Unlimited design freedom – Not shortest leadtime for production Accurate, fine details tool and parts Smooth surface finish (125 RMS) – Not appropriate for most large parts Relatively low tooling costs. (>16”) SLA and 3d Printer output can be used as patterns for Rapid Prototypes. V -Process Advantages Disadvantages Zero Draft – Unit pricing not lowest Smooth surface finish and accurate – Tooling not transferable details Tolerances better than sand cast Thin wall capability Suitable for low to intermediate lot sizes Eliminate secondaries and finishing Lost Foam Advantages Disadvantages Low unit price – Tooling cost and leadtime. Long Tool life – Very few “ job shop” vendors for this Excellent repeatability and consistency production oriented process. Easily produce cored and “undercut” – Used mainly in “core intensive” features automotive plumbing, pump and valve applications. Rapid Prototypes available. Permanent Mold Casting Advantages Disadvantages Low unit price . Long Tool life. Excellent – Need 2-3 degrees draft. repeatability and consistency. – 3/16” minimum wall. High quality , Machinability. Sand Cores – Tooling is more costly than can be used. Sand or –V- Process. Cast Integral Inserts, Sleeves and elements etc Diecasting Advantages Disadvantages High Speed process Smooth surface finish and accurate – Tooling cost details – Tooling leadtime Tolerances best of all casting methods Thin wall capability Suitable for high quantity lot sizes Eliminate secondaries and finishing Dimensionally stable Semi-Solid (SSM) Thixotropic Advantages Disadvantages Low unit price – Very few “ job shop” vendors for this Long Tool life production oriented process. Mainly used in Automotive industry Excellent repeatability and consistency Tooling cost and leadtime “Forging-like” metal properties for – strength and safety critical applications – Sometimes difficult to modify steel tooling Random defects eliminated – Used mainly in automotive, motorcycle and bicycle industries Recap of Processes Reusable Pattern equipment makes impression in compacted or bonded sand Sand dispensable mold. Wax Pattern “invested” in liquid ceramic media and Stucco. Wax removed leaving Investment cavity. Ceramic “fired”, metal poured into cavities created in Shell Reusable Pattern equipment and flask filled with plaster to make impressions. Plaster Mold Dispensable mold halves fired and assembled, then fill with metal. Cavities cut into Steel/Iron then coated with refractory material. Metal is poured Permanent Mold or “pushed” into these reusable molds. Expendable Polystyrene Patterns are enveloped in compacted sand mold. Metal Lost Foam is poured into mold. EPS evaporates as metal fills resultant cavities. Liquid Metal is injected into Hardened Steel Cavities using high pressure Diecast hydraulics. Similar to Diecast. Precisely heated Semi-Solid Billet is transferred into Hardened Semi Solid (SSM) Steel Cavities using high pressure hydraulics. Split (Cope and Drag) Pattern equipment used to make impressions in fine, unbonded sand mold halves. Vacuum is used with plastic films to compact/ hold -V- Process sand mold through molding and pouring cycle. Linear Tolerances Comparison Casting Parting Surface 3 Inches 6 Inches 12 Inches 24 Inches Line Shift Finish Method in inches As Cast (RMS) V-Process ±.014 ±.020 ±.032 ±.056 ±.010 125-150 Sand Cast ±.030 ±.035 ±.060 ±.125 ±.020-.060 250-500 Die Cast ±.006 ±.009 ±.015 ±.027 ±.015 30-60 Plaster Mold ±.015 ±.024 ±.042 ±.078 ±.015 90-125 Investment Cast ±.009 ±.015 ±.027 ±.051 ±.000 90-125 Permanent Mold ±.019 ±.025 ±.037 ±.061 ±.010-025 50-200 Tooling Descriptions Wood, Metal, Urethane Patterns Mounted on Sand Boards. Coreboxes of wood, metal and resin Investment Aluminum Molds to inject wax patterns Urethane Patterns mounted on metal or wood Plaster Mold boards. Coreboxes as required. Urethane Patterns mounted on wood boards, -V- Process Coreboxes as required, urethane or metal. Low alloy Steel Cavities and Mold Frames, slides and cores as required. Permanent Mold Disposable sand cores would require coreboxes. Lost Foam Steel or Aluminum cavities Tool Steel Cavities/Slides, Alloy Steel Mold Diecasting Frames Semi Solid (SSM) Tool Steel Cavities,. Alloy Steel Mold Frames Tooling Cost Complex Average Entry Level $80,000 Lost Foam $50,000 $25,000 $80,000 Semisolid $60,000 $28,000 $80,000 Diecast $50,000 $20,000 $50,000 Perm Mold $25,000 $10,000 $25,000 V Process $9,000 $4,000 $18,000 Investment $6,000 $2,000 $13,000 Plaster Mold $6,000 $2,000 $10,000 Sand $3,000 $1,000 Tooling Lead Times Complex Average Basic or Expedited 20 Lost Foam 14 10 20 Semisolid 16 10 20 Diecast 14 8 12 Perm Mold 9 5 8 V Process 5 3 10 Investment 8 4 8 Plaster Mold 6 4 8 Sand 6 3 Weeks Target Zones for Cast to Machine Datums Commonly referred to as 3-2-1 Datum structure Trade Organizations NADCA - North American Die Casting Association DDC - Diecasting Development Council AA - The Aluminum Association ICI - Investment Casting Institute AFS - American Foundrymen Society SME - Society of Manufacturing Engineers MATWEB.com.
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