Gravity Die Casting Machine

What is a Gravity Die Casting Machine?

The gravity die casting machine (or gravity casting machine) is a highly automated platform that performs gravity die casting methods. It has become a vital part in jobbing foundries over the recent decades in the manufacturing sector owing to its high productivity and flexibility in prototyping and sampling. There are also models designed for mass production on the market. So what does the machine do and what is the gravity die casting process about? Let us take a look.
 

Construction

The construction of the gravity die casting machine includes two reusable molds (typically made of steel), and a base. The full-auto models have a robot arm to pour the molten metal; otherwise, the pouring process is operated manually. Gravity die casting is also called permanent mold casting because of the reusable molds. The cylinders connect to the molds to control the open and close.

The automated gravity casting machines synchronize with a robot arm to perform the pouring process. This process is often assisted by the tilting axis of the machine. The machine tilts the mold to direct the flow of the molten metal. After solidification, the part is retrieved manually or ejected out of the mold automatically. This process is rapid. It only takes minutes for the metal to solidify.
 

Process

Gravity die casting was a process designed specifically for light alloy castings. Gravity in this process refers to the force that spreads the molten metal and fills it into the casting mold. The molten metal is poured down into the mold through a vessel. Since it only uses gravity to spread the liquid, the mold is often tilted during the process to make sure the liquid fills the mold evenly and thoroughly.

Without the turbulence of compressed air or other forms of compression to force the molten metal into the die, the porosity and inclusions are reduced. This feature ensures the utmost properties and characteristics, such as stiffness and strength. Because the metal streams down into the mold through one or multiple channels without compression, it also reduces foaming and oxidation.
 

Advantages

The gravity die casting machine renders great productivity and accuracy. As mentioned in the previous sections, the machine features a fast cycle and automated accessories. Compared with other casting processes or machining methods, the machine is able to manufacture highly accurate parts within a much shorter time. Listed as follows are the advantages in addition to its productivity.
 

High Flexibility

The machine's high flexibility makes it a great solution when it comes to part sampling and prototyping. The design allows various molds to equip on the machine. With only one gravity die casting machine, the shop can carry out a wide range of part designs. Thanks to its high productivity, the machine cuts down the time it takes from modify the parts to the actual production.
 

High Quality

The machine is able to produce high-quality parts because it typically uses high-grade molten metal alloys as the raw material. The high quality also comes from the rapid process. Because the metal solidifies within minutes (could be seconds in cases), the parts can obtain excellent mechanical properties. Besides the material characteristics, this process is able to create complex shapes (more efficient than machining) and therefore guarantees high quality.
 

Applications

The gravity die casting machine is mainly used to process aluminum or aluminum alloys. Aluminum is light but strong and resistant to corrosion and oxidation, makes it a good material for construction equipment, medical equipment, and aerospace parts. The casting products the machine produces include compressors, brake calipers, engine cylinder heads, engine blocks and pistons, valves, kitchen wares, and more.

In sum, the gravity casting machine is suitable for processing products that require higher structural strength, lightweight, resistance, and complex geometries. The industries that use this machine include defense, medical, automotive, aerospace, construction, agriculture, just to name a few. Besides aluminum, it also processes soft metals and non-ferrous metals such as brass, zinc, or magnesium alloys.

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