Product Description and Process
cast aluminum products prototype permanent mold gravity castings
Production process: metal mold gravity casting process
Machining process: CNC machine, machining center, lathe, mill machine, drill machine, etc.
Surface treatment process: anodic oxidation, Dacromet coating, powder coating, etc.
Product Material and Uses
Normally produce with ZL101, ZL101A, ZL102, ZL104, ZL106, ZL107, ZL109, ASTM A356 T6, A319, A413, LM6, LM20, LM25, etc.
The aluminum casting products are widely used for electronic industry, auto-car parts, railway parts, electric motor parts, aero craft parts, watercraft parts, medical treatment equipment, communication system, other machinery components, etc.
GRAVITY DIE CASTING
Sometimes referred to as Permanent Mould, GDC is a repeatable casting process used for non-ferrous alloy parts, typically aluminum, Zinc and Copper Base alloys.
The process differs from HPDC in that Gravity- rather than high pressure- is used to fill the mould with the liquid alloy.
GDC is suited to medium to high volumes products and typically parts are of a heavier sections than HPDC, but thinner sections than sand casting.
There are three key stages in the process.
1 The heated mould [Die or Tool] is coated with a die release agent. The release agent spray also has a secondary function in that it aids cooling of the mould face after the previous part has been removed from the die.
2 Molten metals are poured into channels in the tool to allow the material to fill all the extremities of the mould cavity. The metal is either hand poured using steel ladles or dosed using mechanical methods. Typically, there is a mould “down sprue” that allows the alloy to enter the mould cavity from the lower part of the die, reducing the formation of turbulence and subsequent porosity and inclusions in the finished part.
3 Once the part has cooled sufficiently, the die is opened, either manually or utilising mechanical methods.
Good dimensional accuracy
Smoother cast surface finish than sand casting
Improved mechanical properties compared to sand casting
Thinner walls can be cast compared to sand casting
Reverse draft internal pockets and forms can be cast in using preformed sand core inserts
Steel pins and inserts can be cast in to the part
Faster production times compared to other processes.
Once the tolling is proven, the product quality is very repeatable.
Outsourced Tooling setup costs can be lower than UK sand casting.