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Index:Content
1.
2.
3.
4.
5.
6.
7.
8.

page no.

History.1
Introduction 2
Characteristics of process 3
Process description
Steps of production
Some advantages of this process
Disadvantages
Some casting samples

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1. History:Die casting equipment was invented in 1838 for the purpose of producing movable type for the
printing industry. The first die casting-related patent was granted in 1849 for a small hand
operated machine for the purpose of mechanized printing type production. In 1885, Otto
Mergenthaler invented the linotype machine, an automated type casting device which became the
prominent type of equipment in the publishing industry. The Soss die-casting machine,
manufactured in Brooklyn, NY was the first machine to be sold in the open market in North
America. Other applications grew rapidly, with die casting facilitating the growth of consumer
goods and appliances by making affordable the production of intricate parts in high volumes. In
1966, General Motors released the Acurad process.

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2. Introduction:Gravity Die Casting is a process in which molten metal is poured in a metal mould (usually of
iron) under the working of gravity. Since the metal enters the mould under the infulence of
gravity the process is called as Gravity Die Casting (GDC). Permanent molding in the USA, is
another name used for gravity die casting.
Compared to sand castings, gravity die casting permits the production of more uniform castings,
with closer dimensional tolerances, superior surface finish, and improved mechanical properties.
Metals that can be cast in gravity die casting include Aluminium, Magnesium, Zinc and copper
alloys, and hypereutectic Gray Iron.

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3. Characteristics of process :Gravity die casting is one of the standard processes for the manufacture of high-integrity
automotive castings. It represents proven and absolute precision technology for the production of

large batch quantities. This process is used in carousel casting units or in shuttle technique
particularly for the manufacture of engine castings. Optimum heat dissipation from the
solidifying casting through the die leads to short solidification times. This results in castings
which have good mechanical properties, especially after an additional heat treatment.

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In addition to producing ever more complicated cylinder heads for petrol and diesel engines,
gravity die casting is also used for the manufacture of diesel engine blocks with cast-in grey iron
liners.

4. Process description:In gravity die casting processes, the melt is metallurgically treated in the holding furnace, which
is positioned near the dies.
The quantity of melt for one casting is transported in a ladle and poured into the riser system of
the mould by tilting the ladle. The melt fills the mould cavity smoothly from the bottom up until
it appears in the risers positioned above the casting.

In the example shown, i.e. the casting of a cylinder head, the mould filling and solidification
conditions can be influenced by the design of the gating system and the risers in the top core.
Directional solidification can be forced by using water cooling in the bottom of the die
(combustion chamber area of the head).

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This molding technique is widely used for the manufacture of castings parts made of non-ferrous
alloys such as aluminum, magnesium, copper or zinc. This is mainly due to the low melting
temperatures not exceeding 1000C. For this type of casting, metal is
poured at atmospheric pressure in a permanent mold, made from two machined steel blocks.
Cavity, which will form the final part, is machined from solid block. Each block represents an
half of the final workpiece: the upper mold and the lower mold connected by a parting line
determined during the design phase. The parting line position is essential to remove the part
without damaging the mold or the piece after the solidification phase.
The gravity casting can produce complex parts, sometimes with cavity or pin hole thanks to sand
cores or metal pins.

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4.1 From medium to mass production

To reach the required production rate for high volume markets such as automotive, it is
necessary to provide grip molds, and cooling to accelerate the solidification phase. Because of
the equipment price, this method is not suitable for small series (> 250 parts). For small series we
should choose between permanent mold or sand mold casting. Before starting a series of
molding, the mold must be prepared by a step of die coating. This prevents adhesion of the
molten metal on the mold, and control thermal behavior of the part.
Then the prepared molds are mounted for instance on rotary casting machines.

5. Steps of production:Step 1:- Before starting a series of molding, the mold must be prepared by a step of die coating.
This prevents adhesion of the molten metal on the mold, and control thermal behavior of the part.
Step 2:- Then the prepared molds are mounted for instance on rotary casting machines.
Step 3:- A holding furnace is filled with the molten alloy to flow, and the molds basin is poured
by a ceramic ladle.
Step 4:- When the ladle is empty and the molds basin is full, mold switches to distribute the
metal still in the liquid phase in the mold cavity.
Step 5:- After switching, the mold is kept closed a predetermined period of time: this is the
solidification phase.
Step 6:- The two parts of the mold are opened, and the part is removed.
To finish, the gates are cut and we have a casting part.

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6. Some advantages of this process are :1. A very good dimensional precision thanks to high quality casting tools: the metallic mold
has to be perfectly machined,
2. A good surface, again thanks to the use of a permanent mold and the quality of the
coating,
3. High mechanical properties: effect of higher cooling rate and a shorter solidification time
of the alloy,
4. A smaller overall dimensions of permanent tools in comparison to the non-permanent
mold casting (sand).
5. Aluminium gravity casting is suited to high-volume production. Compared with
aluminium sand casting process, aluminium gravity casting process uses permanent
mould avoiding forming the sand shell moulds for each casting, thus saving considerable
time for the casting process. Furthermore, aluminium gravity casting processes can be
assisted by gravity casting machines, which can increase the production capacity
dramatically.
6. Aluminium gravity casting parts have excellent mechanical properties compared with die
casting parts. Because aluminium gravity casting parts have lower gas porosity.
7. The castings are generally sound, provided that the casting aluminium alloys used exhibit
good fluidity and resistance to hot tearing. Besides, mechanical properties of permanent
mould castings can be further improved by heat treatment.

7. Disadvantages :1. Low volume production compared with die casting.

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Compared with aluminium die casting process, aluminium gravity casting process has a
lower production capacity. Even a gravity casting machine assisted process cannot reach the
high production capacity of the high pressure die casting process. In most aluminium gravity
foundries, handwork is overwhelming. Thus a large order will require a much longer lead
time than that of aluminium die casting process.
2. High tooling cost compared with sand casting.
Gravity casting can also be referred to metal mould gravity casting, for the solid metal
moulds it use. Furthermore, the mould material used is expensive tool steel/iron. Compared
with wooden or aluminium moulds for sand casting, a gravity casting mould is much
expensive. Besides, if the mould is used for a gravity casting machine, ejection system,
cooling system, and sprue system should be added to the mould. That also affects the cost.
3. Minimum wall thickness possible is c. 3-5mm.

8. Some casting samples:This process is commonly used for automotive parts such as engine bracket, torque rod, intake
pipes, cylinder heads, knuckles, brake calipers... We use also the gravity die casting to
manufacture industrial equipment, parts for power transmission that meet sealing standards, for
casings of any kind , or for cable rope hubs.

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