Gravity die-casting, also referred to as Permanent Mold, is a casting process involved in the production of non-ferrous alloy parts. This includes Cast Iron, Aluminum, Zinc, and Copper base alloys. It is most suitable for processes that uses medium to long runs of castings that typically weigh anywhere from 0.5 to 50 kilograms. A majority of the production process involves using manual labor, although it can be automated to a certain amount.
The process of gravity die-casting differs from the other numerous casting processes used. A reusable mold or die having two or more parts is utilized for the production of the castings. This die has the necessary casting impression along with many running, feeding, and venting systems. In order to maintain the efficiency and accuracy of the process, the die is constantly cleared of all debris that accumulates in it.
Gravity die-casting differs from high-pressure die-casting, as gravity is used to fill the mold with the liquid alloy. This process has been employed over decades in producing quality castings. The lack of complicated machinery is one of the features that distinguish it from high-pressure die-casting. Moreover, it can endure the heat treatment of high strength Aluminum alloys, which is something that high-pressure die casting method lacks.
One of the major applications of gravity die casting process is that it can produce core structures that are much complex. For casting small volumes, this is by far the most suitable and economic method, and the accuracy of the casting is still higher in this process than that of other methods. Besides, gravity die casting process is much faster when compared to high- pressure or other die cast processes.
On a sad note though, very little has been done in the form of research in actually improvising this age-old process. It is necessary to have a thorough base and practical experience in other die casting processes before doing a gravity type die cast. However, there are limited opportunities available for properly training new technicians. This is the reason why many gravity die casting companies underperform in their productions.
No matter what, the market demand for quality castings is ensured by the flexibility of the process. This has made gravity die casting more reliable than all the other processes for quality casting productions.