The die-casting sector has become a key player in driving innovation and growth in the automotive industry. Hundreds of different auto parts are designed and manufactured with die-casting. Gravity Die Casting (GDC) has emerged as the most preferred way of designing highly complex automotive parts with precision. It’s also the traditional die-casting process that has been serving hundreds of industries over the decades. The modern automotive industry is heavily dependent on aluminum gravity casting and the die-casting companies.
Let’s explore the significance of aluminum die-casting and GDC in more detail to understand how this manufacturing process has been changing the concept of mobility.
What are gravity casting and aluminum gravity casting?
In the gravity die-casting process, the molten metal like aluminum is filled into the previously designed mold with the help of the gravitational force. In GDC no external or man-made force is used to fill the mold. Since the molten metal flows freely into the mold, the process is a bit time-consuming but brings an advanced level of precision to the finished products. Experts in the industry opine that GDC is the best die-casting process to manufacture complex automotive parts. So, the process follows the following steps in general:
Step 1: In the first step, the pattern is created. This pattern is the replica of the final product. This pattern is generally created with wood or steel. Sometimes, plastics of special quality are used depending on the types of mold to be created and the maximum temperature it needs to withstand during the die-casting process.
Step 2: In the second step, the pattern is adjusted into a two-part metal mold. The mold is generally manufactured with steel or iron. The mold is created to be reusable in multiple casting cycles of the same pattern.
Step 3: The mold’s surface is coated with an intractable material so that the molten metal inside the mold doesn’t stick to it.
Step 4: The mold is now heated homogeneously at a certain temperature so that the molten metal flows into it smoothly.
Step 5: As the mold is completely prepared for the aluminum gravity casting process, the molten aluminum is now poured into the mold systematically. The system is designed to use the force of gravity to pour the mold.
Step 6: As the mold is filled, the molten aluminum is allowed to solidify. The time given for solidification depends on the type of automotive parts to be manufactured. Sometimes the external cooling process is used to solidify the metal quickly.
Step 7: This step is called ejection when the solidified product is separated from the mold.
As the finished product or metal part is now available, the technicians undertake several other steps to give it the desired finishing. Then, the quality control team inspects the whole lot of the products for quality assurance and delivery.
The advantage of aluminum gravity casting
The modern automobile industry demands aluminum die-casting products due to the multiple advantages of aluminum parts and the gravity casting process:
- Aluminum is lightweight by nature but highly stable and rigid. These characteristics of aluminum make the metal parts lightweight and durable. It enhances the overall efficacy of the vehicles including fuel efficiency and control.
- The aluminum gravity casting process is a proven process of manufacturing intricate shapes of hundreds of auto parts for both four-wheelers and two-wheelers.
- Aluminum parts are not only lightweight but also offer enhanced performance and excellent durability of the parts.
- Aluminum GDC makes it feasible for the incorporation of multiple smaller parts into a single uniform structure.
- Aluminum die-casting is an eco-friendly process with minimum carbon emission, the least possible waste, and recyclable waste materials.
Top-notch die-casting manufacturers like Rockman have been manufacturing high-quality international standard products with high demand in both domestic and overseas markets.
No comments yet