Aluminum Castings - Permanent Mold Castings - Gravity Die Castings

<body> <h1>Cast Aluminum</h1> <p> <img alt="Cast Aluminum" src="process/casting2.gif" border="0" align="right" width="250" height="250">Our years of experience with all types of cast aluminum, turning molten aluminum into high quality aluminum castings, is a testament to Ramsden Aluminum's success today.  Utilizing both permanent mold, as well as low pressure permanent mold equipment, we pour large and small castings alike. For sand core projects we produce all of our own cores using a variety of core machines.  In addition, casting in steel inserts, aluminum extrusions, or calrod heating elements routinely form part of the diversity of our casting expertise.</p> <p> With a variety of station molding machines, various sized tilt-pour casting machines, and a number of low pressure permanent mold machines  we can ensure that your shipments are delivered on time rather than being delayed, waiting for compatible molding equipment to become available.</p> <h1><span lang="EN-US">Low Pressure Permanent Mold Castings</span></h1> <p>Similar to the Permanent Mold Casting process, the Low Pressure Permanent Mold Casting process uses a permanent mold made of iron or steel to produce a variety of aluminum castings. Instead of using the force of gravity to allow the metal to flow into the cavity, a low amount of atmospheric gas or air pressure is applied to the molten metal, which is contained in an airtight chamber. This pressure causes the metal to be forced into the mold cavity. With the assistance of the added pressure, the metal fills the mold and compensates for any possible shrinking and casting defects</p> <h2>Some Advantages of Low Pressure Permanent Mold Castings: </h2> <ul> <li>Thin walled casting can be produced</li> <li>Mechanical properties are increased about 5% over Permanent Mold Castings</li> <li>Excellent process for creating intricate designs such as circular patterns</li> <li>Increased surface finish of as-cast castings</li> <li>Higher density castings</li> <li>Low tooling costs</li> <li>Able to produce pressure tight castings</li> </ul> <h1> <span lang="EN-US">Permanent Mold Castings </span></h1> <p class="MsoNormal"><span lang="EN-US">The Permanent Mold Casting Process is a molding procedure that incorporates gravity-induced pressure with rapid solidification to produce both aesthetically pleasing and fully functional castings that have the ability for large volumes of production. </span></p> <h2><span lang="EN-US">Some of the Advantages of using the Permanent Mold Casting Process over the Sand Casting method are: </span></h2> <ul> <li> <p class="MsoNormal"><span lang="EN-US">Able to produce complex shapes and designs</span></li> <li> <p class="MsoNormal"> <span style="font-style: normal; font-variant: normal; font-weight: normal; font-size: 7.0pt; font-family: Times New Roman" lang="EN-US"> </span><span lang="EN-US">Finer grain structure</span></li> <li> <p class="MsoNormal"> <span style="font-style: normal; font-variant: normal; font-weight: normal; font-size: 7.0pt; font-family: Times New Roman" lang="EN-US"> </span><span lang="EN-US">Better mechanical properties including strength of casting</span></li> <li> <p class="MsoNormal"> <span style="font-style: normal; font-variant: normal; font-weight: normal; font-size: 7.0pt; font-family: Times New Roman" lang="EN-US"> </span><span lang="EN-US">Able to achieve a higher as-cast surface finish over the sand casting process</span></li> <li> <p class="MsoNormal"> <span style="font-style: normal; font-variant: normal; font-weight: normal; font-size: 7.0pt; font-family: Times New Roman" lang="EN-US"> </span><span lang="EN-US">High volume production runs</span></li> <li> <p class="MsoNormal"> <span style="font-style: normal; font-variant: normal; font-weight: normal; font-size: 7.0pt; font-family: Times New Roman" lang="EN-US"> </span><span lang="EN-US">Precise and consistent control over dimensional attributes</span></li> <li> <p class="MsoNormal"> <span style="font-style: normal; font-variant: normal; font-weight: normal; font-size: 7.0pt; font-family: Times New Roman" lang="EN-US"> </span><span lang="EN-US">Increased repeatability of casting</span></li> <li> <p class="MsoNormal"> <span style="font-style: normal; font-variant: normal; font-weight: normal; font-size: 7.0pt; font-family: Times New Roman" lang="EN-US"> </span><span lang="EN-US">High quality of surface finish on as-cast products</span></li> <li> <p class="MsoNormal"><span lang="EN-US">Improved definition and detail within parts</span></li> <li> <p class="MsoNormal"> <span style="font-style: normal; font-variant: normal; font-weight: normal; font-size: 7.0pt; font-family: Times New Roman" lang="EN-US"> </span><span lang="EN-US">Ability to design thinner wall thicknesses</span></li> <li> <p class="MsoNormal"> <span style="font-style: normal; font-variant: normal; font-weight: normal; font-size: 7.0pt; font-family: Times New Roman" lang="EN-US"> </span><span lang="EN-US">Competitively priced casting production</span></li> </ul> <p class="MsoNormal"><span lang="EN-US">The Permanent Mold Casting Process consists of pouring molten metal into a permanent mold, usually created from iron or steel. The metal flows into the mould cavity under gravity pressure; flowing into the small crevices of the mold to produce intricate and fully formed castings. </span></p> <p class="MsoNormal"><span lang="EN-US">At Ramsden Industries, we have adapted the process of Permanent Mold Castings in our production procedure to produce castings that suit the wide variety of needs and wants of our customers. Through continuous research and years of molding experience, we are able to use the most current and up-to-date methods of Permanent Mold Casting to be recognized as one of the leading producers of Permanent Mold Aluminum Castings. By creating and designing our own tooling in our sister company, Proto Mould, we are able to utilize and incorporate the newest ideas and innovations into our direct practice. </span></p> <p class="MsoNormal"><span lang="EN-US">By using the expertise of our associates at Proto Mould we are able to offer a full, well-rounded experience for our customers. Also by staying current with industry standards and research we are able to understand the fundamentals of creating the most effective and efficient Permanent Mold Castings processes. For example, by improving the gating of our molds we have been able to produce castings that have higher casting yield with lower scrap rates and lower rates of defects. Our ongoing efforts to continuously improve the quality of our product have greatly benefited our strong customer base.  </span></p> <h1><span lang="EN-US">Semi-Permanent Mold Castings</span></h1> <p><span lang="EN-US">The Semi-Permanent Mold Casting process uses the same general procedures as Permanent Mold Casting but in this process expendable cores of sand or other materials are added to the molding process to create a desired shape or an internal passage. In many cases, the practicality of having a solid casting does not exist. Many customers require that a product have passageways for materials to flow through; therefore a method of creating such passageways must be incorporated. In Semi-Permanent Mold Castings a pre-formed core is inserted into the Permanent Mold cavity. The metal flows around the insert and creates the desired shape or passageway. By using a sand core it allows for the easy removal of the insert to create the desired effect</span></p> <h1>Static Pour Permanent Mold Castings</h1> <h2><span lang="EN-US">Permanent Mold Castings are separated into two major categories of production: Tilt Pour and Static Pour.</span></h2> <p><span lang="EN-US">The Static Pour<b> </b>process is the process in which molten metal is poured directly into the mold cavity. The metal is allowed to solidify in a stationary position. Gravity forces the metal into the mold where it is allotted a set amount of time to solidify before the mold is opened and the casting is removed. The Static Pour process normally has a center-feed pouring method. A center-feed pouring method results when the molten metal is pour directly into the mold from the top, through the gating or a sprue system. This method of Permanent Mold Casting allows for all of the above characteristic, but the main benefit of such a process is the wide range of sizes that can be cast in this format. The size of the parts can range in weight from quite small to very large</span></p> <h1>Tilt Pour Permanent Mold Castings</h1> <h2><span lang="EN-US">Permanent Mold Castings are separated into two major categories of production: Tilt Pour and Static Pour.</span></h2> <p><span lang="EN-US">The <b>Tilt Pour</b> process occurs when the parting line of the mold is set in a horizontal position. A pour basin is attached to the top of the mould. This pour basin is filled in the horizontal position. Once full the mould is tilted to its vertical position to allow for the easy removal of the casting that is produced. Usually set to an automated cycle time, the mould tilts allowing the metal to start to enter the gating or runner system. While the mold is tilting, the metal flows down through the runner system that feed into the cavity of the mold. Allowing the mold to tilt and subsequently having the metal gradually flow into the mold cavity creates less turbulence than would be produced in the Static Pour process</span></p> <p> <nobr><A HREF="processes_size_volumes.shtml" TARGET="" STYLE="{text-decoration: none;}">Permanent Mold Castings - Product size and volume suitabililty</A></nobr> / <nobr><A HREF="design_alloys.shtml" TARGET="" STYLE="{text-decoration: none;}">Mechanical properties of aluminum casting alloys</A></nobr> / <nobr><A HREF="design_engineering.shtml" TARGET="" STYLE="{text-decoration: none;}">Design and Engineering Services for the Aluminum Castings industry</A></nobr> / <nobr><A HREF="heat-treatment.shtml" TARGET="" STYLE="{text-decoration: none;}">Heat Treatment and Aluminum Casting</A></nobr></p> <p> </p> </body>