The graphite permanent mold casting process combines the low cost of 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 graphite molding process is rather simple. Two mold halves with cavities cut out in each half are pressed together, and molten metal is injected into the mold under low pressure. The mold is then, held together throughout the solidification stages of the casting. The mold halves are separated, the casting removed, and the process is repeated.

PROCESS BENEFITS OF GRAPHITE PERMANENT MOLDING CASTINGS:

Cast precision to +/- .005 which reduces secondary machining
Cast surface finish of 125 RMS or better
Zinc/ Aluminum ( ZA12 ) is a 1/3 stronger than aluminum.
Bearing qualities superior to bronze
Excellent detailing and flatness
Tooling leads times of only 3-6 weeks
Porosity free castings

CASTING SIZE for zinc/ aluminum ( ZA -12 alloy ): Lengths up to 16”, widths up to 12” 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 lubricous nature reduces tool wear; these features, along with the process’ near-net shape capabilities, can demonstrate considerable cost savings over the other methods. With in house CNC machining capabilities, we can provide castings complete to print and light assembly.

TOLERANCES: Generally +/- .005”
1st 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° 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.

Mr. Palmer may be reached by calling toll free: 888.494.0414 or email: (dick@castingreps.com)

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