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An outstanding performer in the medium production range is the permanent mold process. For quantities from a few hundred, up to hundreds of thousands, permanent mold aluminum castings often provide the maximum combination of economy and high quality. A look at the nature of the process and the requirements of mechanical equipment reveals the specific reasons that favor the selection of permanent mold aluminum castings.
Gray iron castings are usually thought of as being the cheapest castings available. However, when cost of providing a function is considered, aluminum castings often prove to be more economical or as economical as gray iron castings. When considering the economics of competitive aluminum casting processes, permanent mold casting occupies a unique place. Usually, the cost of a permanent mold casting is less than a sand casting (often substantially less), and usually higher production rates can be obtained. However, the cost of tooling for sand casting is less than that for permanent mold.
When compared to die casting, permanent mold tooling is dramatically lower than dies cast tooling, but piece prices are somewhat higher. It is the combination of these two cost factors, piece price and tooling costs, that enables permanent mold castings to be extremely competitive over a wide range of medium quantity orders.
