Chill casting is a method especially suitable for casting aluminium, magnesium and brass. Alloy is most frequently used for production of ingot moulds (moulds). Before casting, functional surfaces of moulds are treated with special parting kaolin or similar coating. Shapes that cannot be demoulded are often formed using e.g. sand cores. Those are destroyed after the casting. Comparing to sand casting, with ingot mould solidification is achieved faster due to better thermal conductivity. A casting with relatively fine and tight material structure is created which however features better mechanical properties, comparing to a casting of the same material cast in sand.
Benefits of chill casting:
Due to faster solidification, a chill casting features better mechanical properties and relatively fine and tight material structure. Additional benefits are small porousness, accuracy and quality surface. Last but not least, aluminium chill castings are lighter comparing to alloy by almost two thirds of the initial weight. Non-demouldable shapes and sockets can be solved by means of cores. Chill casting represents a good choice for production medium-size castings for series ranging between 1,000 and 10,000 pieces, and minimum production batch of 100 pcs. For higher volumes of parts up to 20 kg weight, we recommend that the low-pressure casting method is applied.
Chill casting capacities:
- castings up to 30 kg weight
- for medium instrument bodies, drive unit lids, stands, etc.
- possibility of inserting brass or steel denseners (nuts, bearing housings, pins, etc.)
- experienced tool works
- service life of ingot mould depends on geometry of casting, alloy and mould material