Foundry Casting Processes
Gravity Die Casting: A Reliable and Precise Technical Choice
At Dejoie Aluminium, we have chosen gravity die casting for the production of our aluminum parts.
This process allows us to manufacture parts with consistent quality, good surface finish, and controlled tolerances, ideal for small and medium series production.
Two Main Categories Stand Out:
Non-Permanent Molds:
The mold is destroyed to remove the part.
Advantages:
Ability to create complex part shapes
Suitable for small series and prototypes
Lower tooling cost
Disadvantages:
Limited production rate
Mold creation takes longer than casting
Low dimensional accuracy
Permanent Molds
The mold, often made of metal, is reused to produce multiple series of parts.
Advantages:
High production rate
Repeatable part geometry
Long tool lifespan
Disadvantages:
More limited shapes, as the part must be demoldable
Long-term investment
Gravity Shell Molding (Process Used at DEJOIE):
- Permanent mold, mainly made of steel
- Alloy poured manually using a ladle
- Capable of producing several thousand parts
- Good surface finish
- Good mechanical properties of the parts
Die Casting:
Similar in principle to shell molding, except the alloy is injected into the mold using a piston or hydraulic actuator.
Technology used for large production runs
Good surface finish
Suitable for producing thin-walled parts
Sand Casting:
A model or pattern plate is molded in frames filled with sand, and the alloy is poured into the cavity left by the pattern.
Suitable for producing complex and large parts, including hollow sections using cores
Ideal for prototyping and small to medium series (from a few units up to several hundred)
Average surface finish and dimensional accuracy
Practical Design Tips for Shell Molding:
Avoid isolated masses
Avoid thickness variations; favor a continuous and uniform flow path
Avoid unnecessary masses
