What is Gravity Die Casting?
Gravity die casting, is a common production process used to produce intricate metal components by utilizing high temperatures and pressure. Gravity die casting is an incredibly versatile process that’s used to make a variety of products, from automotive parts and medical equipment to consumer electronics.
The process is also known as permanent mould casting, and it is commonly used for high-volume production. It is used to produce parts with a high degree of accuracy and smooth surface.
Process of Gravity die Casting
Gravity die casting is a process that has been used for centuries to produce metal parts. The process involves pouring molten metal into a mold under the influence of gravity and allowing it to cool and eventually solidifies over time.
Step 1: Preparation of Molds
The first step in gravity die casting is to create a mold. This mold can be made from a variety of materials, but it must be able to withstand the high temperatures of the molten metal. A two-part sand-casting mold is generally used, consisting of a cam, core, and cavity.
Step 2: Loading of Die
The next step is to heat the metal to its melting point. This is usually done using a furnace or an induction heater. This Molten metal is poured into the die. After the die is loaded, the mold is placed into the die casting machine and with the help of gravity, the molten metal goes into the die cavity due to centrifugal force.
Step 3: Cooling & Solidification
Air circulation systems are used to cool the die quickly and evenly, ensuring uniformity and accuracy of the parts.The mold is then placed in a coolant bath to cool the metal and solidify it.
Step 4: Finishing Operations
Excess metal is then removed with a trim die and the parts are taken out of the mold and inspected to verify quality control. Once the metal has solidified, the mold is removed, and the metal part is ready for use.
| Complex intricate parts can be made |
| Faster process with less setup time |
| More economical option for larger volume of production |
| Used for softer metals such as aluminum and brass |
| High accuracy and repeatable |
| Surface finish is smooth |
| Used to create parts with complex external features |
| Requires higher pressure and heat which increases the process time. |
| High cost of the machinery and more cost of energy usage |
| Used with a wide range of metals, including zinc and magnesium. |
| Provides high precise products |
| Smoother and more precise finish |
MATERIALS
Zastata uses a variety of metals and their alloys for this casting process to produce various types of products There are a variety of metals that can be used in this gravity die casting process, each with its own advantages and disadvantages. The kind of material used to produce the part mainly depends on its application and usage.
The most common metals used in Pressure die cast tool are carbon steel, alloy steel, tool steel, stainless steel. Other materials such as aluminum, magnesium, titanium, copper, nickel, and their respective alloys are also used.
Aluminium : This is a premium material available for gravity die casting. It is very stable and strong, allowing manufacturers to achieve greater complexity in their shapes and designs. Thin walls are also possible. Additionally, aluminum has a low weight and corrosion resistant. It has excellent mechanical properties, electrical and mechanical conductivity.
Copper: Copper is suitable for its high degree of strength, resistance to corrosion and excellent mechanical characteristics Additionally, copper is highly resistant to wear, dimensionally stable and nearly as strong as steel.
Zinc: Zinc make a great choice for clean die casting with a high degree of impact strength, excellent ductility, low cost, smooth plating and low impact on the die itself.
Magnesium: Magnesium has super strength for its weight and is easy to cut, making it excellent for machining. It additionally has the lowest weight of any casting alloy.
Cast Iron: Cast iron is a popular choice for producing pipes, machinery and automotive parts such as gearbox cases and cylinder components. It has relatively low melting point , and got high wear resistance.
Copper alloys such as Yellow brass, silicon brass, manganese bronzes can be used to die cast easily and have high ductility and great mechanical properties.
Aluminium Alloys namely, A360, A380, A383 exhibit greater material properties with ease to production. They are used in automotive components, gear cases, power tools etc. Aluminum alloys are easy to cast and are relatively low in cost.
Magnesium Alloys: Magnesium alloys are popular for components requiring a high strength to weight ratio. They also offer good corrosion protection and are relatively easy to cast, making it an affordable and versatile choice.
Zinc Alloys: Zinc is a soft metal, and its low melting point makes it easy to cast. Zinc alloys are often used for components with complex shapes, such as lock and hinge components.
Inspection methods used to evaluate the quality of gravity die castings depend heavily on the application for which the parts are intended
That’s where Zastata performs Inspection methods and quality testing procedures which include
Visual Inspection: This inspection method is used to check the surface of the forged component for defects, including looking for surface defects, such as chips, scratches, or any other deformities.
Dimensional measurements: They can be taken to determine the accuracy of the dimensions of the parts. Digital tools, such as coordinate measurement machines (CMM), can be used to acquire highly accurate measurements of the parts, allowing for precise and repeatable results.
Non- destructive testing (NDT) may be used to detect any internal or subsurface flaws that may not be visible to the eye. This type of testing involves the use of methods such as ultrasonic testing, magnetic particle testing, and radiography to inspect the castings for any anomalies.
Mechanical testing: It used to examine the mechanical properties of the castings. Tensile, hardness, and impact testing can all provide valuable information about the integrity and strength of the parts. Chemical testing can also be used to check for compliance with required material specifications.
Metallographic/microscopy testing may be used to examine the grain structure of the castings and determine their compliance with standards for mechanical properties.
Optical and digital microscopes may be used to identify any inclusions, porosity, or other defects that may not be visible to the naked eye. This type of testing can also provide valuable insight into the casting process.
Gravity die casting relies on multiple inspection methods to ensure that the resulting castings meet all acceptance criteria. By combining these methods, effective quality control processes can be established, Zastata can help you in reducing production waste and improve the consistency and reliability of the manufactured parts.
Finishing Methods
We also, provide various surface finishing methods to improve the properties and life of the products namely
- Honing
- Polishing
- Buffing
- Electro – plating
- Anodizing
- Powder coating
- Painting
Quality Documentation
Zastata has good understanding and experience with Quality documentation like:
APQP – Advanced Product Quality Planning
FMEA – Failure Mode Effective Analysis
PPAP Level 3 – Production Part Approval Process
SPC – Statistical Process Control
MSA – Measurement System Analysis
Quality Certifications
We work with manufacturers who hold certifications like:
ISO 9001:2015 (Quality Management System)
ISO 14001:2015 (Environmental Management System)
ISO 45001:2018 (OH & SMS)
AS9100 Rev C (Aviation, Space and Defence)
ISO13485:2016 (Medical Devices)
IATF16949:2016 (Automotive Quality Management System)
OTHER TYPES OF CASTINGS
Whilst Pressure die casting is widely used casting method for high volume production, there are other casting methods which have their merits
OUR MANUFACTURER LOCATIONS
Over the years, Zastata has audited and worked with various die casting manufacturer across India for various casting types. Our pressure die casting company are selected and retained based on their quarterly quality performance on Cost, Delivery, Quality, Communication, Innovation and flexibility.
COUNTRIES WE EXPORT
Over the years, Zastata has audited and worked with various die casting manufacturer across India for various casting types. Our pressure die casting company are selected and retained based on their quarterly quality performance on Cost, Delivery, Quality, Communication, Innovation and flexibility.
UK
USA
AUS
Denmark
Germany
Canada
France
China
INDUSTRIES WE SERVE
Advantages:
- Capable of producing parts with tight dimensional tolerances.
- Parts with more thinner walls can be made compared with sand casting method.
- Requires shorter production time with high accuracy.
- Offers high levels of repeatability, i.e., this process allows the manufacturers to produce multiple components in one cycle.
- Suitable for high volume mass production.
Products made from gravity die casting are widely used in most of the industries namely,
- It is widely used in producing automotive parts such as, Engine components, gearbox cases, cylinder head, pistons, electronic equipment’s and structural parts.
- Electronic components for lighting, control panels, consumer electronic products, fixtures, and housing components.
- Military products and communication devices are made using the parts produced from this method.
In short, gravity die casting is an excellent production process for creating highly precise, accurate and defect-free parts.
At Zastata, we have a skilled crew of Engineers and personnels who are expertise in producing a wide variety of metal parts for various industries, such as aerospace, Automotive, oil and gas, and many more. Using a wide variety of machinery and high-end equipment, we produce superior products that offer high performance to become an invaluable asset and support to many manufacturing industries.
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