The One-Shot Casting Process What Is One-Shot Casting?

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The One-Shot Casting Process What is One-Shot Casting? Plaster mold casting is a method of producing aluminum, zinc or magnesium castings by pouring liquid metal into plaster (gypsum) molds. At Armstrong Mold, there are two methods of plaster mold casting: 1) Rubber Plaster Molding (RPM): Patterns create foundry tooling that makes copes, drags and core boxes used to create the plaster molds. 2) One-Shot Casting: Plaster is poured directly on patterns, which are melted out in a furnace cycle. Following is the process for the One-Shot method of making plaster mold castings. Step 1: Model/Pattern 1) Constructed from customer drawing or CAD file. 2) Laser-sintered patterns are produced. 3) Model is engineered to include: A) Metal shrinkage. B) Mold taper (if required) C) Machine stock (if required). 4) We can "clone" or adapt customer-supplied model if requested. Step 2: Plaster Mold 1) A liquid plaster slurry is poured around the pattern. 2) The plaster mold is heated in a furnace to melt out the pattern and cure plaster. Step 3: Pour Casting 1) Molten metal is prepared by degassing, and a spectrographic sample is taken to check the chemical analysis. 2) The molten metal is then poured into the plaster mold. 3) The plaster is removed by mechanical knock-out and high pressure waterjet. 4) When the casting has cooled, the gates and risers are then removed. Step 4: Secondary Operations 1) The raw castings are inspected and serialized. 2) Castings may then require (per customer specifications): A) Heat treatment B) X-Ray C) Penetrant inspection 3) After finish inspection, casting is ready for: A) Machining B) Chemical film, chromate conversion, paint special finishes D) Assembly E) Form-in-place gasketing. ARMSTRONG MOLD CORPORATION • 6910 MANLIUS CENTER ROAD, EAST SYRACUSE, NY 13057 • 315-437-1517 • FAX 315-437-9198 .

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Casting Processes
2.4_3 Casting Processes • pouring a liquid material (molten metal) into a prepared mold • materials: iron steel aluminum brass bronze magnesium certain zinc alloys • iron is used most often - fluidity, low shrinkage, strength, rigidity, and ease of control Chap 2, Casting – p. 1 • Six factors of the casting process: 1) A mold cavity must be produced. - must have desired shape - must allow for shrinkage of the solidifying metal - a new mold must be made for each casting, or a permanent mold must be made 2) A suitable means must exist to melt the metal. - high temperatures - quality mix - low cost 3) The molten metal must be introduced into the mold so that all air or gases in the mold will escape. The mold must be completely filled so that there are no air holes. 4) The mold must be designed so that it does not impede the shrinkage of the metal upon cooling. 5) It must be possible to remove the casting from the mold. 6) Finishing operations must usually be performed on the part after it is removed from the mold. Chap 2, Casting – p. 2 Seven major casting processes: 1) Sand casting 5) Centrifugal casting 2) Shell-mold casting 6) Plaster-mold casting 3) Permanent-mold casting 7) Investment casting 4) Die casting Sand Casting • sand is used as the mold material • the sand (mixed with other materials) is packed around a pattern that has the shape of the desired part • the mold is made of two parts (drag (bottom) & cope (top)) • a new mold must be made for every part • liquid metal is poured into the mold through a sprue hole • the sprue hole is connected to the cavity by runners • a gate connects the runner with the mold cavity • risers are used to provide "overfill" Chap 2, Casting – p.
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