permanent mold

Question 1

What are the three permanent mold casting processes?

Answer 1

• die casting
• squeeze casting
• centrifugal casting

Question 2

It is a permanent mold-casting process in which the molten metal is injected into the mold cavity under high pressure.

Answer 2

die casting

Question 3

What is die casting?

Answer 3

It is a permanent mold-casting process in which the molten metal is injected into the mold cavity under high pressure.

Question 4

In die-casting, the molds are called ______

Answer 4

dies

Question 5

What are the two main types of die casting?

Answer 5

1. hot chamber
2. cold chamber

Question 6

In this type of die casting, the metal is melted in a container attached to the machine, and a piston is used to inject the liquid metal under high pressure into the die.

Answer 6

hot chamber die casting

Question 7

In this type of die-casting, the molten metal is poured into an unheated chamber from an external melting container, and a piston is used to inject the metal under high pressure into the die cavity.

Answer 7

cold chamber die casting

Question 8

This process is limited in its application to low-melting point metals that do not chemically attack the plunger and other mechanical components.

Answer 8

hot chamber die casting

Question 9

In hot chamber die casting, the metals it works on are ___________.

Answer 9

zinc
tin
lead
magnesium

Question 10

What are the advantages of die-casting?

Answer 10

• high production rates
• economical for large production quantities
• close tolerances possible
• good surface finish and dimensional accuracy
• fine grain structure and good mechanical properties are achieved (due to rapid cooling)
• thin wall parts and intricate shapes may be cast (thin sections)
• small size parts may be produced

Question 11

What are the disadvantages of die casting?

Answer 11

• high initial cost
• not applicable for high melting points
• large parts cannot be cast
• some gases may be entrapped in form of porosity

Question 12

It is a combination of casting and forging in which molten metal is poured into a preheated lower die, and the upper die is closed to create the mold cavity after solidification begins.

Answer 12

Squeeze casting

Question 13

What is squeeze casting?

Answer 13

It is a combination of casting and forging in which molten metal is poured into a preheated lower die, and the upper die is closed to create the mold cavity after solidification begins.

Question 14

Squeeze casting is also known as __________.

Answer 14

liquid- metal forging

Question 15

What are the advantages of squeeze casting?

Answer 15

• little or no waste material
• complex designs
• fine microstructure with higher strength components
• good surface texture and low level of porosity
• improve performance of lighter alloys
• products have a long service life
• good surface finish
• low shrinkage
• used for both ferrous and non-ferrous alloys

Question 16

What is the common application for squeeze casting?

Answer 16

automotive parts

Question 17

What are the disadvantages of squeeze casting?

Answer 17

• high tooling and die cost
• low flexibility of tooling
• accurate control is needed

Question 18

It refers to several casting methods in which the mold is rotated at high speed so that centrifugal force distributes the molten metal to the outer regions of the die cavity.

Answer 18

Centrifugal casting

Question 19

What is centrifugal casting?

Answer 19

It refers to several casting methods in which the mold is rotated at high speed so that centrifugal force distributes the molten metal to the outer regions of the die cavity.

Question 20

What are the three types of centrifugal casting?

Answer 20

1. true centrifuge casting
2. semi centrifugal casting
3. centrifuge casting

Question 21

In this type of centrifugal casting, the molten metal is poured into a rotating mold to produce a tubular part.

Answer 21

true centrifugal casting

Question 22

Examples of parts made by true centrifugal casting:

Answer 22

pipes, tubes, bushings, rings

Question 23

In this type of centrifugal casting, the centrifugal force is used to produce solid castings, rather than tubular parts.

Answer 23

semi centrifugal casting

Question 24

Example of casting made by semi-centrifugal casting.

Answer 24

wheels and pulleys

Question 25

In this type of centrifugal casting, the mold is designed with part cavities located away from the axis of rotation, so that the molten metal is poured into the mold is distributed to these cavities by centrifugal force.

Answer 25

centrifuge casting

Question 25

In this type of centrifugal casting, the mold is designed with part cavities located away from the axis of rotation, so that the molten metal poured into the mold is distributed to these cavities by centrifugal force.

Answer 25

centrifuge casting

Question 26

What are the advantages of centrifugal casting?

Answer 26

• great strength
• increased product purity
• better production cost- efficiency
  -suitable for mass production
• no cores are used
• gating system, runner, and riser are eliminated

Question 27

What are the disadvantages of centrifugal casting?

Answer 27

• impurities in the internal diameter of small diameter pipes are very hard to remove.

Question 28

What are the disadvantages of centrifugal casting?

Answer 28

• impurities in the internal diameter of small-diameter pipes are very hard to remove
• not suitable for every metal material
• solidification time and temperature
• distribution is difficult to determine
• limited size component and shape design
• more maintenance and skilled operators are required