Features of Design of Chill Molds for Casting of Non-Ferrous Metal

Abstract

The article discusses methods for calculating the main parameters of the chill mold in the design process. Formulas for calculating the thickness of the working wall, as well as recommendations for choosing the material of the chill mold, depending on the size and shape of the resulting castings, are specified. Disadvantages of existing methods for calculating the chill mold parameters are indicated. Solutions for the use of multi-layer coatings applied by physical vapor deposition on the forming surface of the chill mold are proposed, which increases the efficiency of the casting process in the chill mold, regardless of the shape of the casting and the design of the chill mold.

Features of Casting Magnesium Alloys in Chill Mold

“…It is worth noting that for castings obtained in chill mold, it takes 2 times less time for thermal operations in comparison with similar castings obtained by casting in sand-clay molds [20]. The explanation for this may be the fine-grained structure of the chill mold castings.…”

The Principle of Choosing the Composition of the Protective Coating for Die Casting Molds

“…These requirements can be met through the use of multilayer coatings applied by physical vapour deposition [24], [25]. This type of coating should consist of at least two layers: the upper one, which provides a decrease in temperature on the forming surface, and the lower one, which creates compressive stresses (Fig.…”

Effect of Coatings on the Performance of Injection Molds

“…The small thickness of the coatings, which is from 3 to 10 microns, does not allow a positive change in the components of the thermal balance. When using molybdenum as the basis of a multilayer protective coating, it allows only 0.3% improvement in the performance of the supplied heat [20].…”