Gravity Die Casting

Inox Gravity Die Casting

Whether you`re looking for an expert in the gravity die casting process or the finished products, Inox Cast is your best choice as a trusted partner. With 20-years of expertise in this field, we are professional in customized and nonstandard gravity die casting, CNC, or molding process.

Inox Gravity die casting is a permanent die casting process. This process has an excessive rate than aluminum sand forming. Thus, it offers numerous advantages including the probability of fine grain sizes and low gas porosity that can be accomplished.

This process actually works for light alloy and metal die casting. Inox gravity die casting is one of the first processes to be developed for this application.

What`s more, the process can be perfectly automated. This creates high-quality and dense castings with superior mechanical aspects like stiffness and strength. That way, it is very ideal for demanding motorized applications.

If your business concentrates on casting any metal parts for automotive, construction, and other applications, gravity die casting equipment and its finished products from Inox is great for you.

Inox Cast, established in the year 1997 is willing to help and guide for a better business future! Giving you satisfying efforts, products and guidance is the core of our company.

With 20 years of experience, we have grown and gained about 1000 active employees. Most of them are mature technical staff and senior managerial personnel.  All are customer-oriented and willing to guide you all the way.

For more information about Inox Gravity Die Casting, you can message us right away!

Gravity Die Casting: The Ultimate FAQ Guide

With gravity die casting, you can make a range of products depending on your unique requirements and specifications.

This guide answers all questions you have been asking about gravity die casting.

So, keep reading to learn more.

What Is Gravity Die Casting?

Gravity die casting refers to a casting method that involves pouring the molten metal from a vessel into a mold.

The only force you need during the pouring phase is gravity hence its name.

You can control the filling process by tilting your die.

The resulting casting process is a high-quality surface finish with stronger mechanical properties.

Gravity Die Casting Process

How Does Gravity Die Casting Work?

The gravity dies casting process utilizes a manual process for most production steps.

However, you can have automation in specific processes which facilitate its production.

Tilting the die is the primary way in which you can control the filling direction and the speed.

Four main steps take place in gravity die casting.

These steps are:

Die Heating

You start the process by cleaning the die.

This removes any impurity that affects the quality of your production.

You have to heat the die before spray coating it.

This is to help in temperature control of the die during the fabrication process.

Spray coating also helps in removing the cast after completion.

Pouring Molten Metal

You pour the molten metal into the die.

This is primarily a manual process, though, in large-scale production, you can automate it.

The process utilizes gravitational force only hence its naming.

After pouring the metal, you allow it to solidify.

Removing The Cast

Once the die is cool, you have to remove the cast.

This is also a manual process unless you can use mechanical processes in specific large-scale production processes.

Mechanical processes involve the use of ejector pins.

Surface Finish

This process involves removing gate runners, flash, and sprues from the casting.

You also have to remove the parts’ sharp edges and unwanted materials.

Blast cleaning ensures your components retain their dimensions while removing impurities.

You can apply a surface coat to enhance its visual appeal.

The last step involves packaging and shipping the component to your final consumer.

How Gravity Die Casting Works

What Are The Benefits Of Gravity Die Casting?

Using gravity die casting has the following benefits:

High Volume Production

Gravity die casting is an ideal option for casting high-volume components.

The advantage of this method is it allows for automation which facilitates large-scale production.

Low Cost

The cost of production using gravity fie casting is relatively low compared to other casting options.

The process does not utilize many materials, and there is less energy consumption during the production process.

This is because the molten metal flows through the use of gravity.

High-quality Components

Gravity die castings produce high-quality components.

These components are durable and can withstand various environments.

Gravity allows for the compactness of the material as it flows.

Gravity Die Casting Is A Low-Cost Method

Are There Any Limitations To The Use Of Gravity Die Casting?

Yes. Using gravity die casting has the following disadvantages:

High Cost Of Purchasing

The cost of purchasing the machine is relatively high compared to other casting machines.

You also have to factor in the cost of purchasing the mold and the casting elements.

The maintenance cost is also high since you have to replace the mold and cast frequently.

This makes the overall cost of gravity die casting higher.

Element Production Limitation

Gravity die casting is not the best option for producing components with a high melting point.

Therefore, you must check on the component you want to fabricate and the material you are using in the casting process.

Where Can You Use Gravity Die Casting?

Gravity die casting is an ideal method for various industrial and automotive parts.

Such parts include brake clippers, cylinder heads, turbos, knuckles, engine pistons, and blocks.

You can also use this method to produce various kitchen tools and lighting components.

What Are The Alternative Die Casting Methods Apart From Gravity Die Casting?

Besides gravity die casting, the leading die casting methods are low-pressure die casting, vacuum die casting, squeeze die casting, and semi-solid die casting.

The choice of which die casting method to use depends on several factors.

For instance, you have to consider the cost of casting using a given method.

Casting cost includes purchasing the materials for casting and the actual casting process.

You also have to consider the type of component you are producing.

Specific casting methods are ideal for producing smaller parts, while others can produce significant components.

The type of material you are using also affects the casting selection process.

Aluminum material is the best material for casting using gravity die casting.

Stainless steel is best suitable for casting using low-pressure die casting.

Aluminum Is The Best Material For Gravity Low casting

However, you need to prioritize quality regardless of the casting method you select.

How Do You Minimize Solidification Shrinkage In A Gravity Die Casting?

You can minimize solidification shrinkage by allowing sufficient cooling time for your component.

Rapid cooling is the leading cause of solidification shrinkage since the component does not take solidify properly.

What Are The Common Defects Of A Gravity Die Casting?

You are likely to experience the following defects when using gravity die casting:

Gas Porosity

This defect arises from turbulences due to high fluid speed when filling.

Turbulence causes air formation, which can be a problem during solidification.

The limitation of air is they cause cavities which make the component have weak resistance.

These bubbles appear round, shiny, and opaque.

This depends on the type of gas that is entrapped when filling.

gas Porosity

Shrinkage Porosity

This is a defect that arises when the cast is solidifying and cooling.

This is because of the shrinking of the material, which is common in large components.

As the material solidifies, it tends to move towards cooler areas.

Due to the temperature variation between the core and casting surface, cavities tend to form on the inner part of the component.

These cavities have an angular shape appearance.

Inclusions

There is a possibility of intermetallic compounds forming during the fabrication process.

Such compounds cause defects during the mechanical and finishing stages.

When you have such defects, you tend to spend more during the finishing process.

This is in terms of the tools you need for the machining process.

Inclusions Are One Of The Defects From Gravity Die Casting

There is a possibility of these defects causing cracks on the component due to fatigue and stress.

Superficial Defects

These defects appear on the surface of your component and are highly visible.

This affects its aesthetical appearance.

It is hard to remove these defects, resulting in a low-quality component.

Cold Laps

These defects are due to irregular molten metal flow and low temperature.

They appear as flow marks on the surface of your component, lowering its quality.

Cold laps occur when two or more matching material flows interact.

The interaction is due to oxide formation, dirt inclusion, or low temperature.

Lamination

This type of defect occurs when there is an overlapping of two layers during the filling phase.

It is not easy to detect this defect during die casting.

This is because they appear during the surface finishing your cast.

Lamination affects the quality of your metal part.

Which Materials Can You Use On Gravity Die Casting?

Aluminum is the primary material that you can use in gravity die casting.

You can also opt for aluminum and aluminum cast material.

How Does Gravity Die Casting Compare To Sand Die Casting?

The mold in gravity die casting consists of stainless steel.

This allows you to have more cavities on the mold, depending on the dimensions of your component.

The mold in sand die casting is mainly from the sand.

This minimizes the molding dimensions limiting you to the product dimensions you can produce.

There is a limitation on the products you can produce using sand die casting.

This is due to the quality of its mold and the dimensions.

Sand Die Casting Process

Sand die casting is an ideal option for the production of smaller parts.

You can use gravity die casting to produce medium to high volume components.

The accuracy of gravity die casting is relatively higher than sand die casting.

This is due to the accuracy of the production processes.

Gravity die casting results in the production of high-quality components with minimal errors.

This reduces the overall production cost while enhancing efficiency.

Sand die casting results in a lower surface finish than gravity die casting.

You, therefore, have to perform surface finish procedures on sand die casting, which increases the cost of production.

Both sand and gravity die casting are used in different industries to produce various tools and parts.

What Is The Cost Of Gravity Die Casting?

The actual pricing of gravity die casting depends on the following factors:

Size Of Your Component

The larger the size, the higher your gravity die casting cost.

This is due to the molding material you require and the size of the cast.

The design of your component is critical in determining its size.

Casting Material

Gravity die casting utilizes different materials such as aluminum and aluminum cast.

These materials cost differently, hence selecting a material that fits your budget.

Tooling Cost

Tooling costs include machine and surface finishing tools.

These tools give the final appearance of your component.

What Is The Difference Between Gravity Die Casting And Pressure Die Casting?

The significant difference between gravity die casting and pressure die casting is the force required during the filling phase.

Gravity die casting uses gravity as the force required during the filling phase.

Pressure die casting requires enhanced pressure to pump the molten fluid when filling the cast.

Do You Require Surface Finishing When Using Gravity Die Casting?

Yes. You require a surface finishing for your gravity die casting.

The surface finishing gives you the final appearance and ensures its exact dimensions.

There are different surface finishing methods for your selection.

The choice depends on cost and the final appearance you require for your component.

What Are The Parts Of A Gravity-Die Casting Machine?

Your gravity die casting process machine should have the following parts:

Heating Chamber

The heating chamber is where there is melting of the metal material.

Melting is critical in ensuring you have the right state of the material for the casting process.

The heating temperature depends on the melting point of the metal.

Mold

The actual casting process takes place in the mold.

The mold consists mainly of stainless steel due to its high melting point.

There are different designs for your mold, depending on the dimensions of your cast.

Cooling Chamber

The cooling chamber is where the cast cools after molding.

The duration in which a component cools within this chamber varies depending on the type.

How Do You Compare Tilting Technology To Horizontal Or Vertical Mold Opening In Gravity Die Casting?

Both methods allow for the flow of molten metal into the mold.

However, tilting technology gives high pressure on the die-cast hence a faster casting process.

The casting quality for vertical mold opening is higher than that of tilting technology.

This is due to the molding time it takes.

What Affects The Molding Time In A Gravity Die Casting?

The main factors affecting the molding time in gravity die casting are:

Material Feed Rate

The feed rate of the molten metal depends on the gate valve and the gravitational force.

This is because no external pressure forces the metal to flow.

A higher feed rate reduces the molding time.

However, this can affect the quality of your part.

It is vital that the feeding rate compliments the molding and cooling processes for quality production.

The Gate Area.

This is an area that allows for the flow of the molten metal.

You can increase its size to increase the amount of molten metal flowing or decrease it to reduce the flow rate.

You, however, need to maintain the quality of your component by having a constant gate area of your casting machine.

Part Dimensions

Complex dimensions require a higher molding time compared to simple parts.

This is because these parts have to get sufficient molten metal before cooling.

Thermal Conductivity Of The Die And Alloy

Thermal conductivity helps in the molding and cooling processes.

Higher thermal conductivity means you have a lower molding time.

However, the thermal conductivity should be so that it allows for the part formation and compactness.

What Are The Considerations In Selecting Gravity Die Casting?

The primary considerations when you are selecting gravity die casting are:

Size Of Component

Gravity die casting is the best option if you are producing smaller components.

This is due to the resulting compactness and quality of production.

The products you can manufacture using gravity die casting are automotive parts such as brake pads.

Material For Your Part

The material you select for producing your component determines the selection of gravity die casting.

Typical materials for using gravity die casting are aluminum and aluminum cast material.

Cost Of Production

You have to evaluate the overall cost of producing your component using gravity die casting.

The cost should be affordable in comparison to the other casting methods.

Is Machining Necessary In Gravity Die Casting?

Yes. Machining is a necessary part of gravity die casting.

Machining helps in removing the excess metal from your component.

This gives the part its shape while facilitating its functioning.

The main machining methods for application on your gravity die casting are:

Cutting

Cutting involves the use of single or multiple cutting tools.

It is an ideal process for machining

Abrasive Processes

The primary process involves here are sand casting and grinding.

These methods allow you to machine your part into the required shape and dimensions.

The advantage of this method is its effectiveness and relatively cheaper.

This is in purchasing the tools and the machining process since you don’t have to contract a professional.

The major limitation of this method is its slow process.

This limits its use, especially when machining high quantities of your orders.

Non-traditional Processes

This involves using certain chemicals in machining your component in gravity die casting.

Non-traditional processes also involve the use of electrical processes.

The advantage of non-traditional processes is they are fast and effective.

However, they are costly since you have to purchase the chemicals before applying.

Improper machining using this method can also result in distortion of your part.

This can increase the production cost since you have to start over again.

How Do You Maintain A Gravity Die Casting Machine?

Cleaning Is A Way Of Maintaining The Gravity Die Casting Machine

There are various ways of maintaining your gravity die casting machine.

For instance, you have to constantly clean the machine’s surface before and after every casting process.

Impurities can cause several defects on your cast component, thereby compromising quality.

Repairing and replacing your mold is also an integral part of maintenance.

The mold tends to wear out hence the need to replace it to maintain the quality of your component.

Proper maintenance also involves tightening loose screws and nuts on your machine.

This enhances the durability and performance of your machine.

Lubrication is also critical in the maintenance procedure since it ensures the moving parts are free and reduces friction.

What Is The Material Of The Mold In Die Casting?

The primary material for mold fabrication in gravity die casting is stainless steel.

This is due to its high melting point, making it hard to melt when molding the other parts.

Other Useful Resources are:

Cold Chamber Die Casting Process

Vacuum Die Casting Process

Low-Pressure Die Casting Process

Hot Chamber Die Casting Process

For any questions or inquiries about gravity die casting, contact us now.