With permanent mold casting, tooling cost is a significant percentage of the initial investment in a start-up job. As a result, mold life plays an important role in the foundry's determination of casting cost for the customer. In an era when casting jobs can be won and lost with quotes that differ by pennies, permanent mold foundries must look for every opportunity to extend the life of their permanent mold tools to increase job profitability. One measure used to increase mold life (and casting quality) is mold cooling systems. Using either air or water, these systems regulate heat flow to ensure the production of sound castings and prolong mold life. This article will examine both air and water permanent mold cooling systems and discuss the advantages and disadvantages of both. In addition, a common problem for permanent molds due to improper temperature control-cracking and erosion-will be explored to provide solutions for foundries.
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