Aluminum gravity casting and sand casting process is always used for heavy part with big wall thickness and very strong mechanical property after T6 heat treatment. Its also better to avoid porosity inside casting after secondary machining. Gravity casting part is nice looking with better surface than sand casting, but sand casting is more flexibility even it is very complicated shape. 356 T6 is the most common raw material.

Core making machine

Resin sand core

Aluminum sand casting model

From:http://www.chinaaluminiumcasting.com/aluminum-sand-casting-75-1.html

die casting can refer to any kind of casting using a die such as gravity die casting or low pressure die casting, yet here die casting only refer to high pressure die casting. Aluminum die casting is a process of casting Aluminum alloy under pressure, which can produce precision parts in high volume at low costs.

1.Advantages of die casting process

1.1 high volume but low cost Compared with aluminum sand casting and gravity casting, aluminum die casting can produce precision parts in high volume at low costs.
1.2 good surface finish and good dimensional accuracy,Aluminum die casting generally has good surface finish and good dimensional accuracy. For many parts, post-machining can be totally eliminated, or very light machining may be required to bring dimensions to size.

2.Disadvantages of die casting process

2.1. higher cost of die casting mould, The cost of tooling of die casting is much more expensive than those as sand casting, gravity casting and investment casting.

2.2. high porosity, Though the porosity of die casting can be adjusted by using much higher pressure with a much larger and heavier mold, the porosity can not be avoided and is much more than that is made with low pressure casting and gravity casting. Furthermore,porosity leads die casting parts to be not suitable for heat treatment.Thus the consistence can not be compared with gravity castings.

Aluminium Die Casting

Aluminium Die Casting

Aluminium Die Casting

Aluminium Die Casting

Aluminium Die Casting

We are the professional Pressure Die Casting ,aluminium & aluminum pressure die casting,Low pressure die casting in China.

Die cast tooling called insert die, die casting dies, or die casting molds, comes in many styles, sizes, and values. Die cast tooling comes in single cavities (one part each cycle) or multiple cavities (more than one part each cycle). INNOVAW only uses cold chamber die casting machine tooling dies or molds for aluminum die cast parts.

Glossary of die cast tooling terms:

Draft – Required angle perpendicular to the parting plane to allow the die cast parts to eject.

Aluminum casting design

Aluminum casting design includes raw casting design with die casting mold, finish production design involving post machining and other surface finishing such as electroplating, electrophoresis, painting, anodizing and powder coating. Casting design is not a simple and plain working only invloving die casting mold and raw casting. We need to take into consideration every manufacturing steps

Zinc die casting design

There two kinds of die casting processes available for zinc high pressure die casting. Commonly we cast samll zinc die cast products by hot chamber die casting machine, and larger parts by cold chamber die casting machines. Thus before we start zinc die casting design, we will confirmed with customers which kinds of machine he prefers. Eecept of this issue, the design of zinc die casting is quite the same as that of aluminum die casting

Simulation analysis for mould design

R&D software

• 3-d design software:Solidworks; Pro-engineer,Autodesk inventor, UG
• 2-d design software: AutoCAD
• Handling file formates: igs, stp, step, dxf, dwg, and any formates can be handled by above softwares
• Mold flow analysis of die casting mold(3D flow simulation)
• CAD Systems:
  Cimatron
  Solid Works
  AutoCad / CADKey
• CAM Systems:
  Cimatron
  Virtual Gibbs
  Esprit

From:http://www.chinaaluminiumcasting.com/pressure-die-casting-47-1.html