Gravity Die Casting

Gravity Die Casting

Gravity die casting is also one of the oldest known processes for fabricating metals and metal alloys. It's a good choice for large series production, large or thick parts, high detail levels, simple castings, uniform wall thickness, and high volume levels.

Gravity die casting is a permanent mold casting process that involves pouring molten metal into a mold using gravity. The mold is usually made of cast iron or steel, and the metal is poured from a ladle or vessel. The mold cavity fills with metal using only gravity, and the process can be controlled by tilting the mold. This process is also known as permanent mold casting.

Gravity die casting has several advantages:-

• No external force is required to push the molten metal into the mold.
• Gravity die cast components have better density than sand casting parts.
• Gravity die cast parts have less porosity and better grain structure than sand casting parts.
• Gravity die cast components have good mechanical properties, which are ideal for heat treatment. 
• Gravity die cast components have a better surface finish than most other casting parts.
• Gravity die casting is cheaper than other processes like vacuum casting and squeeze casting, especially for medium or small volume production.
• Gravity die casting is a metal casting process that uses gravity to fill a mold with molten metal. Here's an overview of the process:

Steps involved:

• 1. Pattern creation: A pattern, typically made of wood or metal, is created to shape the mold.
• 2. Mold preparation: A permanent mold, usually made of steel or cast iron, is prepared and coated with a release agent.
• 3. Melting: The desired metal alloy is melted in a furnace.
• 4. Pouring: The molten metal is poured into the mold through a pouring system.
• 5. Solidification: The metal solidifies under gravity, taking the shape of the mold.
• 6. Ejection: The casting is removed from the mold after solidification.

Advantages:

• - High accuracy and surface finish
• - Good mechanical properties
• - Can produce complex shapes
• - Relatively low cost

Common applications:

• - Automotive parts (engine blocks, cylinder heads, gearboxes)
• - Aerospace components
• - Industrial machinery parts
• - Medical equipment

Materials used:

• - Aluminum alloys
• - Copper alloys
• - Zinc alloys
• - Steel alloys

Limitations:

- Limited to relatively small castings

- May require additional processing (e.g., machining) for complex geometries