This process is fully automated. It helps reduce labor costs and increase product efficiency. So the CNC machines (computer numerical control machines) shape the die, and gravity pours melted aluminum into it. Besides this, the mold cavities are filled with melted aluminum, shaping it into the mold. Special algorithms on automated machines help in the creation of various innovative designs. So, they drive the demand for the aluminum gravity die-casting process. Additionally, aluminum gravity die casting doesn’t solely utilize aluminum metal. It uses aluminum alloys i
n its applications.
Here is a step-by-step explanation of every step involved in aluminum gravity die casting.
- Design and Preparation
The aluminum gravity die casting starts with designing the patterns. We need to make a prototype or replica of any product. So, these patterns are usually made up of metal or wood. Besides this, these patterns consist of precise dimensions and design specifications. So, it helps make the mold highly accurate. Moreover, the die sections mainly consist of two halves. These are generally made up of steel or cast iron. One is known as a stationary mold, and the other is known as an ejector mold. These halves are allowed to fit perfectly into each other. So, it creates a cavity that replicates the pattern shapes.
- Die Setup
Once the patterns develop, the very next step is die setup. It is highly useful to make molds or dies for the casting process. So, it is important to undergo a thorough cleaning first. It will help remove any debris or residue from previous casts. Additionally, it must guarantee that the molten aluminum will smoothly flow inside the machine. After that, the die is preheated to a particular temperature. This preheating is also useful for thermal shock. So, it will increase the metal flow. Consequently, it will increase the lifespan of the die.
- Preparation of Molten Aluminum
The aluminum is allowed to melt inside the furnace. This process requires a temperature of around 700 °C (1292 °F). So, the furnace has enough heat to melt down the aluminum. Besides this, a few alloys are also added to increase the strength and durability of the aluminum metal parts. Additionally, degassing is also performed to remove hydrogen and other impurities from the molten aluminum. So, all these operations make the aluminum durable and also help avoid porosity. Thus, it increases the strength of finished products.
- Casting Process
After this, the sating process starts. The molten aluminum is allowed to pour into the gravity die cavity. It is usually carried out using a carefully designed pouring basin and runner system. After that, gravity guarantees an even distribution if the metal slows in all parts of the die cavity. So, when the molten aluminum cools down, it solidifies and attains the shape of the die cavity.
- Ejection and Post-Processing
The next step is ejection. The aluminum gravity mold opens, and the solid aluminum part comes out of it using ejector pins. Moreover, this process needs extra care to avoid any damage to the metal part.
Besides this, the post-processing comprises removing the excessive material and giving a smooth finish to the aluminum parts. So, it involves trimming and fettling. It helps remove the excessive materials, i.e., the gating system, runners, and risers. It is usually done using different machining methods. They may include sawing, grinding, or machining. Moreover, the finishing of the material part also uses heat treatments. So, it can increase the part’s mechanical properties.
- Finishing and Coating
The final stage is finishing and coating the aluminum part. It is usually done to increase the aesthetic of cast parts. Besides this, finishing and coating both increase the durability of the metal part. appearance and durability. Multiple treatments are used to make a proactive oxide layer over the aluminum part surface. These treatments increase corrosion resistance. So, they may include painting or powder coating. These coatings give metal parts a pleasant and smooth look. But also, it increases strength.
