Gravity Die Casting Process

Gravity Casting Process for Automotive & Transportation Parts & Components  

When it comes to automotive parts and transportation components, you need to partner with a foundry who has the strongest, best quality, most effective, and most reliable equipment and materials. This is why we utilize proven casting and development processes that deliver you the components and equipment pieces you know are up to the job. This is where the gravity die casting process comes in. 

Gravity die casting is a form of die casting, usually deployed in conjunction with non-ferrous alloys such as copper, zinc, and aluminum. The process results in ultra-strong, ultra-durable alloy fabrications that are ideal for heavy-duty use. Our customers then deploy these components and equipment pieces in high-pressure, high-strain environments, where they perform with aplomb.

The Gravity Die Casting Process

Phase One: The Mold

The mold is critical to the success of the process. Sand cores are used to craft the shape of the mold, or die, in order to achieve a perfect fit for your component. This sand casting procedure helps us to translate even your most complex needs into a suitable component. The mold is then heat-treated so it can withstand the high temperature of the molten metal. Then a die release agent is applied so the component can be easily removed from the mold on completion.

Phase Two: Molten Metal Pouring

Molten metal is poured into the mold, and the casting process begins. 

Phase Three: Manipulation

For more complex component shapes, it may be necessary to manipulate the molten metal within the mold cavity. This is achieved by tilting and maneuvering the mold so the metal reaches each and every recess within the cavity.

Phase Four: Cooling

With the metal material in place, cooling can begin. The cooling process hardens the metal within the mold in order to cast a highly resilient, ultra-durable finished component, ready for the stresses and strains of operation. Once the metal is sufficiently cooled, the component is removed from the die.

Phase Five: Refining

There will typically be rough or sharp edges on the component after its removal from the die. During the refining phase, these elements are removed, and the finished component is made ready for use.

Our Value Proposition

What are the advantages of gravity die casting with Densen Group  foundry? Here are a few of the advantages you can expect when you choose us for your component casting project.

Efficient Processes for High Volume Production

If you need a high volume of components for your project with in-house refining services, our processes are designed to accommodate this. Using the procedure outlined above, we can secure repeatable results with a high degree of accuracy, enabling us to deliver what you need over and over again, all from the same location. 

Cost-effective Operation

The gravity die casting process delivers results that meet and exceed domestic and international standards. What’s more, it achieves this in a cost-effective and highly efficient way. This means we can offer you competitive pricing on your gravity die casting manufacturing and fabrication project. You can enjoy an attractive pricing schedule without worrying about the suitability of the finished product.

High Component Quality

All of the components we provide go through a meticulous production process, as well as rigorous testing, to ensure that the mechanical properties and structural integrity of the finished product are of the highest quality. We are committed to providing our customers with what they need, and this includes attaching a quality guarantee to every project we work on.

At Densen Group, we deploy a precision casting team who will ensure that the gravity-casted components you receive are fit for purpose, compatible with your existing equipment, and of the highest quality possible.