Custom High Precision Casting Cast Aluminium Parts Sand Casting ASTM A356

OEM Permanent Mould Cast Aluminium Parts ZL101 102 T6 CNC Machining

Product Description and Process
Aluminum Permanent Mould Casting Gravity Casting ZL101 102 T6 Treatment Aluminum Foundry

Production process: green sand casting process, pre-coated sand casting process
Machining process: CNC machine, machining center, lathe, mill machine, drill machine, etc.
Surface treatment process: anodic oxidation, Dacromet coating, powder coating, etc.

Product Material and Uses
Normally produce with ZL101, ZL101A, ZL102, ZL104, ZL106, ZL107, ZL109, ASTM A356 T6, A319, A413, LM6, LM20, LM25, etc.

The aluminum casting products are widely used for electronic industry, auto-car parts, railway parts, electric motor parts, aero craft parts, watercraft parts, medical treatment equipment, communication system, other machinery components, etc.

GRAVITY DIE CASTING
Sometimes referred to as Permanent Mould, GDC is a repeatable casting process used for non-ferrous alloy parts, typically aluminum, Zinc and Copper Base alloys.
The process differs from HPDC in that Gravity- rather than high pressure- is used to fill the mould with the liquid alloy.
GDC is suited to medium to high volumes products and typically parts are of a heavier sections than HPDC, but thinner sections than sand casting.

There are three key stages in the process
1 The heated mould [Die or Tool] is coated with a die release agent. The release agent spray also has a secondary function in that it aids cooling of the mould face after the previous part has been removed from the die.
2 Molten metals are poured into channels in the tool to allow the material to fill all the extremities of the mould cavity. The metal is either hand poured using steel ladles or dosed using mechanical methods. Typically, there is a mould “down sprue” that allows the alloy to enter the mould cavity from the lower part of the die, reducing the formation of turbulence and subsequent porosity and inclusions in the finished part.
3 Once the part has cooled sufficiently, the die is opened, either manually or utilising mechanical methods.

Advantages
Good dimensional accuracy
Smoother cast surface finish than sand casting
Improved mechanical properties compared to sand casting
Thinner walls can be cast compared to sand casting
Reverse draft internal pockets and forms can be cast in using preformed sand core inserts
Steel pins and inserts can be cast in to the part
Faster production times compared to other processes.
Once the tolling is proven, the product quality is very repeatable.
Outsourced Tooling setup costs can be lower than UK sand casting.

What is Gravity Die Casting?

Gravity Die Casting is a permanent mold casting process, where the molten metal is poured from a vessel or ladle into the mold. The mold cavity fills with no force other than gravity, filling can be controlled by tilting the die. Undercuts and cavities can be incorporated into the component form with the use of sand cores. This process gives a better surface finish than sand casting as well as better mechanical properties, both due to rapid solidification.

Additionally, this process has a higher casting rate than aluminum sand casting; however, the metal molds are a higher cost than sand. Advantages of this process include the possibility of low gas porosity, and fine grain sizes can be achieved.

Compared to sand casting, this process requires less finishing and fettling and gravity die casting tends to produce a higher quality product. The Gravity die casting production method is generally less cost effective in the manufacture of tooling compared with sand casting.

Gravity Die Casting Process

Gravity die casting is often a manual process, with the molten metal added with the use of a ladle. However, for some high volume applications it is also possible to use an automated ladle to pour the molten metal. The speed and the direction of the filling can also be controlled by tilting the die.

Apart from the method by which the molten metal is poured into the die cavity, and the gravity die material, the casting process is essentially the same as sand casting. It involves four steps:

The die is heated and then sprayed with a refractory coating, and closed. The coating both helps control the temperature of the die during manufacture and it also assists in the removal of the casting.

Molten metal is then manually poured into the die, (although in some cases a machine can be used) and allowed to solidify.

The die is then opened and the cast parts either removed by hand or in some cases ejector pins are used on the mechanised machines.

Finally, the scrap, which includes the gate, runners, sprues and flash, is removed from the casting(s). The castings are then processed to remove sharp edges and excess material, then blast cleaned (if required) prior to dispatch to the customer.

Gravity die casting is a natural partner to sand casting, and allows us to offer the customer the most cost effective route for casting manufacture.

Gravity die casting allows us to create high quality parts and components to even the most exacting of customer specifications. We produce aluminum gravity die castings for OEM. We are able to produce quality aluminum gravity die castings for a range of industries, including High Horsepower Diesel Engines, Defense, Gas Turbines, Machine Tools, Compressors, Pumps, Valves, Medical Equipment, Light Construction Equipment, Articulated Trucks, Photo Imaging and Printing.

A380 Aluminum Alloy
The most popular alloy for aluminum die casting is A380. We use A380 because it has demonstrably the best combination of physical and mechanical properties for casting, including being lightweight, very strong at high temperatures and corrosion resistant. A380 is also very good at retaining dimensional stability even with complex shapes and thin walls and offers high electrical and thermal conductivity.
A383 Aluminum Alloy
Another option for die casters is to use A383 aluminum alloy. This is alloy is typically only used when you are forming intricate components and require very specific die-filling characteristics. While it doesn’t share all the properties of A380, it does offer higher strength at high temperatures with less chance of cracking under heat.
A360 Aluminum Alloy
A360 is harder to cast than A380, which is why many die casters avoid it. However, it does offer higher strength at high temperatures, better ductility and higher corrosion resistance, so you may want to consider this alloy depending on your casting abilities and needs.
A360 vs. A380 v. A383
To summarize the differences between the three types of casting alloys as outlined above, A360 has the best pressure tightness, high-temperature strength and corrosion resistance of the three alloys.
A380 is also highly corrosion-resistant but more cost-effective and easier to work with than A360, so this is the one you would use most commonly if you have budgetary concerns to consider and don’t need the highest levels of corrosion resistance or pressure tightness.
A383 is a modified A380 alloy you would only use if you need precise die filling that you are not getting from your A380 alloy, as it is not as durable as A380.

319 Aluminum Sand Castings
Aluminum alloy 319 is a 6% Si and 3.5% Cu alloy with 1.0 Fe maximum. It has excellent casting and machining characteristics. Corrosion resistance and weldability are very good. Mechanical properties are good in both the heat-treated (T5) and non-heat treated conditions.
The anodized color is generally gray with a brown cast depending on the amount and ratio of silicon and copper.
Typical applications for sand casting 319.0 are a wide variety of structural castings for engine parts, engine crankcases, gas and oil pans, and general commercial applications.

Typical Mechanical Properties

Chemical Composition (%)

Typical Applications