Ceramic Mold Casting Process: Ceramic mold casting process is a casting process in which refractory ceramic material is used as a mold material.
Because of the refractory ceramic material, the metals having higher melting point can also be casted by this method.
In manufacturing industries, components like machining cutters, metalworking dies, metal molds, and impellers can be manufactured by using Ceramic Mold Casting Process.
Ceramic Mold Casting Process (Steps)
The step by step procedure for the Ceramic mold casting process is shown below.
- First of all, the mold materials are combined for the mold preparation.
- The mixture of fine grained zircon (ZrSiO4), aluminum oxide, fused silica, bonding agents, and water is made which is known as slurry.
- This slurry is poured over the casting pattern and it is allowed to set for some time.
- The pattern which is in the slurry, is removed and the mold is allowed to dry.
- The mold is baked in the furnace to remove the moisture content from it.
- After that, the ceramic mold is fired. Due to this, the unwanted material gets burnt off and ultimately the strength and hardness of the ceramic mold increases.
- Because of firing the mold, the microscopic cracks are developed in the mold material. These cracks give permeability and collapsibility to the ceramic mold, which are necessary for the casting process.
- After this, the other half of the mold is also made and its assembly is done.
- After getting assembly done, the ceramic mold is backed up with fireclay material which gives additional strength to it.
- Now the ceramic mold is preheated and the molten metal is poured into the ceramic mold cavity.
- The molten metal is allowed to solidify and finally the casting component will be ready.
- For removal of the casting from the ceramic mold, the ceramic mold is destroyed.
Having said that, let’s discuss advantages and disadvantages (pros and cons) of ceramic mold casting process.
Advantages of Ceramic Mold Casting
Advantages of ceramic mold casting process are mentioned below.
- Ceramic mold casting is advantageous for manufacturing the components having thin sections.
- Accurate dimensions can be obtained by using this process.
- As the components have good accuracy, the machining process is minimum.
- Smooth surface finish can be obtained by ceramic molding process.
- It is also possible to make the components weighing upto 700 kg by using ceramic mold casting process.
- Ceramic molds are resistive to very high temperatures.
- Ceramic molds have good permeability as they possess micro cracks that are produced by firing the ceramic mold.
Disadvantages of Ceramic Mold Casting
Disadvantages of ceramic mold casting process are mentioned below.
- Ceramic mold casting process is expensive as it has more equipment cost.
- Production rate is slow because the mold preparation is time consuming.
Applications of Ceramic Mold Casting
Applications of ceramic mold casting process are mentioned below.
- Ceramic mold casting process is used for casting the ferrous metals and other metals having high melting point.
- Various tooling components like drop forging dies, die casting dies, stamping dies, extrusion dies, glass molds, injection molding dies, etc. can be manufactured using ceramic mold casting process.