ALUYONIX Precision Die Casting
CASTING PROCESS METHODOLOGY

Gravity Die Casting / Permanent Mould Casting

Reliable gravity-fed permanent mould casting for heavy-duty structural components.

Process Metallurgy & Overview

Gravity Die Casting relies solely on gravity to introduce molten metal into tiltable or static iron/steel permanent dies. Combined with sand cores, it produces intricate internal passages and deep hollow cavities impossible in HPDC.

Working Principle & Operational Steps

1Reusable metallic mold is preheated and coated with refractory ceramic release wash.
2Internal sand cores (Croning or Cold-box) are placed for hollow hydraulic passages.
3Metal is poured manually or through robotic tilt-pour mechanisms to control turbulence.
4Progressive cooling produces uniform fine grain structure followed by mechanical mold opening.

Technical Parameter Specifications

Clamping Force
Mechanical and Hydraulic Tilt Units (up to 1,500 mm platen)
Wall Thickness
3.5 mm – 45.0 mm
As-Cast Tolerance
±0.20 mm to ±0.50 mm
Cycle Rate
5 – 15 shots/hr
Surface Finish
Ra 4.5 – 8.0 µm
Primary Alloys
Aluminium A356, AlSi12

Ideal Applications

  • Heavy diesel engine cylinder blocks and cylinder heads
  • High-voltage electrical switchgear housings and busbar clamps
  • Hydraulic brake calipers and master cylinders
  • Industrial pump impellers and fluid handling volutes

Key Advantages

  • Moderate tooling costs (30–50% lower than HPDC dies)
  • Can accommodate expendable sand cores for complex internal channels
  • Fully heat-treatable (T4, T5, T6) achieving yield strengths over 240 MPa
  • Economical for medium volumes (500 to 25,000 parts/year)

Engineering Trade-offs

  • Thicker nominal walls required (typically > 3.5 mm)
  • Slower production rate and manual cycle intervention
  • Lower dimensional tolerances requiring finish CNC machining on mating faces

Evaluate Feasibility for Your Part in Gravity Die Casting

Submit your 3D STEP or PDF model for instant DFM analysis and tooling quote.

Request Gravity Die Casting Quote