Get an Overview of Gravity Die Casting

For metal and light alloy die casting, gravity die casting was one of the very earliest processes to be invented. This is a fully automated process and from a ladle, the molten metal is poured directly into a permanent or semi-permanent die.

To reduce oxidation and foaming the goal is to fill the die with minimum turbulence through one or more channels. This decreases porosity and inclusions, providing optimum metal characteristics in the final casting.

Benefits of the tilting gravity die casting process

One major benefit of the tilting gravity die casting process is that with excellent mechanical attributes like strength and stiffness it can produce dense, high-quality castings. For demanding automotive applications like brake systems and suspension components that make it very suitable.

Major benefits of Gravity die casting technologies include:

In the mold, sand cores can be placed as a result gravity die casting can also produce parts with complex shapes.

For small and medium volume production-minimum investment is required

It produces parts with excellent mechanical properties that are even used for heat treatment

It is suitable for high-volume, automated production

Application

For diverse complex aluminum casting production of automotive parts such as engine cylinder heads, brake calipers, knuckles, turbos, engine blocks, and pistons gravity die casting technology is an ideal option. It even suits many other industries too starting from lighting components to kitchen tools.

Know whether Gravity Die Casting is Cost-Effective or not

For medium and high-production products, Gravity dies casting is reasonable by cost. Due to the high initial capital cost of the die itself when a low volume of parts is required the cost per unit starts increasing.

For gravity die casting manufacturers that need a high volume of parts, it becomes the best option. It allows a broad selection of different metal alloys to select from and allows for reliable, repeatable parts that provide consistent quality as well. For manufacturers that need thin walls, strength, low weight, corrosion resistance, conductivity, and good mechanical properties Aluminum gravity die casting is one of the most popular and versatile choices. It is even a relatively affordable alloy to select from.

Everything You Need to Know About Permanent Mold Casting

In the process of permanent mold aluminum casting, into the steel die the molten metal is poured and it flows only at the force of gravity. For the maximum part, by pouring the molten metal into the top of a die that has been made in the desired shape of the casting permanent mold castings are produced. In actual casting practice, there are many deviations from this simple approach.

Sometimes at the top, the metal is poured into the mold, but into the die that conveys the molten metal to the side or bottom of the casting cavity itself a runner is cut, so that during filling the metal flow is from the bottom or side of the mold. This is performed to optimize casting conditions for the part that is being produced.

At different times by permanent mold casting aluminum manufacturer to achieve controlled filling of the mold the metal may be poured into a basin beside the die and then the entire unit is tilted. Two of the main criteria for successful casting production by the permanent mold process are the flow of metal into the die cavity and the flow of heat from the metal to the die during solidification.

From hardened steel dies for the permanent mold process are produced. Compared to ceramic molds the heat transfer rate is higher and is used in other processes and in casting cycle time this provides advantages.

You will find that in the casting that cannot be produced with conventional steel dies; the casting design requires undercuts or hollow cavities. In these cases, for the permanent mold process, the die designer may choose a loose piece or an expendable core. Semi-permanent mold casting is referred to as a process when there is the use of expendable cores.

The benefits of the permanent mold casting aluminum and semi-permanent mold casting processes are reasonable piece costs achieved from the high production rates with metal molds (especially water-cooled molds) when compared to sand and investment casting, and when compared to low-pressure and high-pressure die casting there is the lower investment required for equipment. In the semi-permanent mold, casting the use of expendable cores permits great design flexibility for castings.

Know About Aluminum Die Casting

What is Aluminum die casting?

• Due to high-pressure systems, Aluminum Gravity Die Casting is accomplished by forcing molten metal into a mold from Corrosion resistant
• A manufacturing process that produces defined, accurately, smooth, and textured-surfaced metal parts
• Have strength-to-weight ratio and good stiffness
• Based on rapid production
• Allows a high volume of die casting parts to be produced very quickly
• Compared to other alternative casting processes it is more cost-effective
• Highly conductive

For complex part geometries and thin walls, aluminum gravity casting alloys are lightweight and posses high dimensional stability. It provides high thermal and electrical conductivity has good corrosion resistance and mechanical properties hence making it a good alloy for die casting. To the die casting industry's low-density, aluminum metals are essential.

Processes of Aluminum die casting 

This process implements a steel mold that in rapid succession is capable of producing tens of thousands of castings. To permit the removal of castings the die must be made in at least two sections. The casting cycle starts on two die halves being clamped together tightly. Into the die cavity, molten aluminum is injected where it solidifies quickly. In a machine, these sections are mounted securely and are arranged in a way that one is stationary while the other is moveable. The casting is ejected and the die halves are drawn apart. Depending on the complexity of the casting, die casting dies can be simple or complex, having moveable slides, cores, or other sections.

Aluminum gravity die casting manufacturer observed various reasons for aluminum being the most commonly cast non-ferrous metal in the world. For utilizing aluminum die casting, the most popular reason is that very lightweight parts can be created without sacrificing strength. Aluminum dies cast parts, as Compared to other non-ferrous materials bear higher temperatures and have more options of surface finishing. Aluminum die-cast parts have good stiffness and strength-to-weight ratio, are corrosion resistant, and highly conductive.

Characteristics and Advantages of Aluminum Die Castings:

• Great Resistance to Corrosion
• Fully Recyclable and Reusable in Production
• Excellent Electrical Conductivity
• Lightweight and Durable
• Good Strength-to-Weight Ratio

Hire the best aluminum gravity die casting manufacturer online.