Gravity Die Casting Overview, Process, Applications, and Advantages

Gravity die casting, also well-known as permanent mold casting, is a method for casting different types of high-quality parts covering the range of low-temperature metals. Dissimilar to pressure die casting, gravity die casting is all about pouring the liquid metal into a particular mold or shape with no extra power applied. Likewise, dissimilar to pressure die casting, gravity die casting can utilize both metal and sand cores, alluded to as semi-permanent casting, for more intricacy of designs. 

Gravity Die Casting: the process at a glance

Gravity die casting is much of the time a manual cycle, with the liquid metal added with the utilization of a ladle. Nonetheless, for some high-volume applications, it is also possible to utilize a computerized ladle to pour the liquid metal. The speed and the heading of the filling can likewise be constrained by shifting the die. Aside from the strategy by which the liquid metal is filled the die cavity, and the material, the casting process is basically equivalent to sand casting and includes the following 4 stages:

1. The die is heated and afterward splashed with a recalcitrant covering, and shut. The covering not only controls the temperature of the die during production but also aids the evacuation of the casting.
2. Liquid metal is then poured into the die, (albeit at times a machine can be utilized) and permitted to harden.
3. The die is then opened and the cast parts either eliminated manually or at times ejector pins are utilized on the automated machines.
4. At last, the scrap, including the gate, runners, sprues, and flash, is taken out from the casting(s). The castings are then handled to eliminate sharp edges and overabundance material, then, at that point, impact cleaned (whenever required) preceding despatch to the client.

Gravity die casting is considered to be a natural partner to sand casting and capacitates the manufacturers of parts and components to provide their clients with the most cost-effective way of getting suitable castings.

Is Gravity Die Casting a Great Option for Mass Production?

When gravity die casting first came into existence after efforts of many years, manufacturers would make use of this technique to create only simple components rather than complex ones. But, over the years, technology progressed rapidly and the sand cores were introduced in the field of gravity die casting. As of today, manufacturers of different components can create even the most complex parts by making use of the gravity die casting process. However, there are a large number of other methods also which can be used to produce parts on a large scale, and that too, very rapidly. Many manufacturers are adopting those methodologies to serve their purposes of mass production.
 
Notwithstanding, it is fundamentally less expensive than most other different casting procedures. Although this technique calls for more time, it saves a great deal of money since the infrastructure for gravity die casting costs less. Additionally, this technique is more straightforward than most other casting procedures. So choosing gravity die casting for the large-scale manufacturing of less difficult components is a better decision.

But, it might prove to be a matter of great loss if the manufacturers utilize this technique for an enormous volume of complicated parts creation. If the creation volume is little or medium, the gravity die casting technique is an ideal choice over most other casting procedures.

What Are the Applications of Gravity Die Cast?

With a rapid progression in the field of technology, it has now become possible to create even the most intricate and complex parts by making use of gravity die casting methodology. A large number of industries including automotive, lighting, and kitchen components make use of this process to shape a large number of parts and appliances.

Some of the most common gravity die casting applications might include but are not limited to the following:

• Parts and components used in the automobile sector such as engine pistons, blocks, cylinder heads, brake calipers, etc.
• Different types of lighting parts such as LED lighting housings, and base materials
• Different components used in the kitchen like spoons, pots, etc.

Where can you find examples of gravity die-cast components?

The procedure or technique of gravity die casting has witnessed a sea change over the past few decades. Today, gravity cast parts and components can be seen even in the most complex sectors of engineering. Some of them include the following:

• Electronics
• Consumer appliances
• Complex machinery
• Automotive
• Defense
• Marine, and
• Structural and architectural applications.

Some of the top advantages that gravity die casting offers

Needless to say, gravity die casting offers a large number of advantages when compared to other casting procedures. Given below are some of the most salient advantages that give this revolutionary technique an edge over other casting methodologies:

High production rates

The complete automation of the gravity die casting technique makes it possible for manufacturers to produce hundreds of castings in a single day.

Dimensional accuracy

The castings achieved through this methodology are both durable as well as dimensionally stable.

Versatility

Making use of the gravity die casting technique, manufacturers can easily create even the most intricate shapes that are perfectly suitable for different types of complex parts.

High tensile strength

Gravity die casting is considered to be ideally suitable for all heavy-duty mechanical applications, particularly when it comes to giving heat treatment.

Multiple finishing options

When there is a requirement for an extremely smooth or textured surface, the gravity die casting procedure calls for only a slight amount of after-work in the production cycle. 

Concluding Remarks

As a leading manufacturer and supplier of extremely complex aluminium precision casting, Caparo India has been offering a complete spectrum of solutions from the concept to the production stage for many decades. The company holds a proven track record of serving global clientele with its reliable, efficient, and quality aluminium casting solutions. Caparo has established a world-class Aluminium foundry wherein it manufactures intricate Aluminium castings through High Pressure Die Casting and Gravity Die Casting processes. The facility is manned by more than 850 employees who have unmatched capabilities in design and engineering complemented by new-age technology and facilities such as tailor welded blanks.