GRAPHITE PERMANENT MOLD CASTING ZINC ALUMINUM CASTINGS

The Graphite Permanent Mold casting process combines the low cost of easily machinable graphite molds with a high-strength zinc-aluminum alloy, ZA-12, to provide an economical alternative to other casting processes in annual volumes of 500-15,000 pieces per year.

The process of casting Graphite Permanent mold parts is simple: Two mold halves with cavities cut in each half, are pressed together, molten metal is injected into the mold under low pressure and held at pressure throughout the solidification stages of the casting. The mold halves are then separated and the casting is removed. The process is then repeated.

PROCESS BENEFITS OF GRAPHITE PERMANENT MOLDING CASTINGS:

• Cast precision (+/-.005), which reduces secondary machining
• Cast surface finish of 125 RMS or better
• Zinc/aluminum, ZA12, is one third stronger than aluminum
• Bearing qualities superior to bronze
• Excellent detailing and flatness
• Tooling leadtimes of 3-6 weeks
• Porosity free castings

CASTING SIZE - Lengths to 16 inches, widths to 12 inches and combined depths to 4 inches. These dimensions are maximum limits and are not to be combined.

MACHINING – ZA-12 is an easily machined material and its lubricious nature reduces tool wear; these features, along with the process’ near-net shape capabilities, can demonstrate considerable cost savings over other methods. In house CNC machining capabilities to provide castings complete to print and light assembly is also available.

TOLERANCES -

• Generally +/- .005
• First inch: +/.005
• Additional inches: +/-.002” per inch
• Across parting line add: +/-.005

MINIMUM WALL THICKNESS – Usually .100”; however, .060” is possible on small sections.

MINIMUM DRAFT – 2 degrees on surfaces perpendicular to parting line.

Please contact Dick Palmer to learn more about how we can work together to help to reduce your company’s costs using either the Graphite Molding process or, other casting processes. Dick may be reached toll free by telephone at: (888) 494-0414 or, by emailing: dick@castingreps.com

Please feel free to view a list of companies represented including the Graphite Permanent Mold Castings industry or process .