A chill mold is a detachable mold designed for multiple uses. The name has French roots and translates as a shell or shell. The technology of chill casting of aluminum and other metals has been known to man for more than one decade and is widely used in all industries. It is one of the standard methods for manufacturing complex castings for the automotive and other industries. This method is a proven technology for mass production of high-precision parts using automated casting processes.
Features of aluminum die casting
This technology primarily allows the use of the same mold many times (up to several hundred). This feature is an important difference from aluminum casting in the CTS, which involves preparing a molding mixture and making a disposable mold from it. Detachable half-molds provide optimal heat removal from the cooling melt. At the same time, the time for making castings is significantly reduced. This allows you to obtain parts with high surface quality and specified mechanical properties, which can be adjusted during additional heat treatment.
The process of die casting requires preliminary preparation, which consists in cleaning the half-molds from the remnants of auxiliary coatings and other contaminants. In addition, the strength of fastening of all moving parts, as well as the locking mechanism, is checked. After a complete check of the die, non-stick and other protective coatings are applied to its surface and only then proceed to the direct pouring of metal.
When using this technology, it is possible to both force-cool the castings to increase productivity and ensure the necessary holding time of the parts at high temperature by applying facing coatings to the mold to reduce heat transfer. The adjustment of the cooling time depends on the layer thickness and the materials used.
Of course, this process has its advantages and disadvantages. The advantages include the possibility of multiple use of molds, high quality of products both in terms of roughness and compliance with geometric dimensions. At the same time, due to the simplicity of automation, casting of aluminum alloys in a chill mold allows you to abandon many operations for processing castings. Due to this, it is possible to reduce the cost of production and increase the productivity of the technological process.
The disadvantages of aluminum casting in a metal mold include the rather high cost of equipment. At the same time, more complex castings require high labor costs, which also affects the cost of production. In addition, even reusable molds sooner or later wear out and need to be replaced, which requires additional costs.
The versatility of the technology This casting method is widely used in all branches of the foundry industry, from the manufacture of parts for automobiles to aircraft construction. Die casting is used when working with various types of metals, but aluminum and its alloys are the most common.
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