Shenzhen Alu Rapid Prototype Precision Co., Ltd.

Steps in Gravity Die Casting:

1.Mold Preparation:

A metal mold (or die), typically made of steel or cast iron, is designed with the shape of the desired part. The mold consists of two or more parts that can be separated to remove the casting.

The mold is cleaned and coated with a refractory material (e.g., ceramic or graphite-based coating) to protect it, improve metal flow, and facilitate part release.

The mold may be preheated to a specific temperature (e.g., 150–300°C, depending on the alloy) to reduce thermal shock and improve casting quality.

2.Molten Metal Preparation:

The metal (commonly aluminum, magnesium, or zinc alloys) is melted in a furnace to a precise temperature, typically between 600–750°C for aluminum.

The molten metal is degassed or treated to remove impurities and trapped gases, ensuring a high-quality casting.

3.Pouring the Metal:

The molten metal is poured into the mold through a gating system (channels designed to direct the flow) using a ladle or automated pouring system.

Unlike high-pressure die casting, gravity die casting relies solely on gravity to fill the mold, so the pouring is controlled to avoid turbulence and ensure proper filling.

4..Solidification:

The molten metal fills the mold cavity and begins to solidify. The mold’s metal construction helps dissipate heat, allowing controlled cooling.

Cooling rates are managed to minimize defects like shrinkage or porosity. Sometimes, cooling channels in the mold or external cooling methods are used.

5.Mold Opening and Part Removal:

Once the metal has solidified (typically within a few minutes), the mold is opened, and the casting is removed, either manually or with ejector pins.

The mold’s design ensures easy part release, and the refractory coating helps prevent sticking.

6.Finishing:

The casting is trimmed to remove excess material (e.g., sprues, runners, or flash).

Additional processes like machining, polishing, or surface treatments (e.g., anodizing or painting) may be applied to achieve the desired finish and tolerances.

7.Mold Reuse:

The mold is cleaned, inspected, and recoated as needed before being reused for the next casting cycle. Metal molds can withstand thousands of cycles, making the process cost-effective for medium to high production volumes.