Gravity cast aluminum parts

Core Product & Service: Molds for Gravity Cast Aluminum Parts

Our core business focuses on the customized design and manufacturing of high-precision molds for gravity cast aluminum parts, which are core production equipment for realizing forming of aluminum components via gravity casting technology (relying on aluminum melt's own gravity for filling). Our core function is to deliver durable, high-performance molds that adapt to gravity casting's characteristics—ensuring smooth, uniform aluminum melt filling, precise dimensional control of thick-walled parts, and excellent structural integrity, which are critical for components demanding load-bearing capacity, wear resistance, and long service life. Backed by a professional team of 35+ engineers and technicians, we leverage advanced CAD/CAM/CAE software (UG, AutoCAD, SolidWorks) to conduct in-depth simulation of the gravity casting process. This includes simulating melt flow velocity, filling sequence, and solidification process to optimize mold cavity structure, pouring system (sprue, runner, gate), exhaust layout, and mold temperature control design, thereby preventing common defects such as misrun, cold shuts, and internal porosity. Our molds are tailored to match the properties of gravity casting-adaptable aluminum alloys (e.g., A356, A380, 6061, 6063) and the production needs of diverse industries, featuring exceptional high-temperature resistance, stable casting performance, and extended service life.

Production Process & Supporting Technologies

The production of our molds for gravity cast aluminum parts adheres to a strict industrial-grade standardized workflow, optimized for gravity casting's low-pressure filling characteristics: 1. Demand Analysis & Custom Design (Collaborate with clients to confirm component specifications (especially thick-walled structure requirements), performance requirements, aluminum alloy material selection, and production capacity; conduct 3D mold modeling and CAE gravity casting simulation to verify melt filling uniformity, structural integrity, and defect risk, and optimize the pouring system design); 2. Raw Material Preparation (Select high-quality mold steel (H13, SKD61, P20) with superior high-temperature resistance and wear resistance, suitable for gravity casting's relatively low filling pressure but long-term high-temperature contact; implement precision cutting via CNC flame cutting equipment); 3. Precision Machining (Perform CNC milling, grinding, EDM, wire cutting, and high-speed machining to ensure the machining accuracy of mold cores, cavities, and pouring components, with key dimensions controlled within ±0.005mm; focus on mold分型 surface precision to prevent aluminum melt leakage);4. Assembly & Custom Debugging (Skilled technicians conduct manual assembly, install customized exhaust and temperature control systems (e.g., mold preheating channels), and perform multiple rounds of trial casting debugging to optimize parameters such as mold preheating temperature (200-300℃), pouring temperature (680-750℃), and pouring speed); 5. Quality Inspection & Delivery (Use coordinate measuring machines (CMM), X-ray flaw detectors, and tensile testing equipment to inspect mold dimensions and internal quality of trial castings; conduct load-bearing and wear resistance tests to ensure compliance with industrial standards and provide detailed test reports). In addition to mold design and fabrication for gravity cast aluminum parts, we also offer supporting processes such as post-casting machining (milling, drilling, tapping, grinding), surface treatment (anodizing, powder coating, electroplating), and finished product assembly. We also provide high-pressure die casting molds and plastic injection molding services to meet clients' diversified manufacturing needs.

Common Problems & Solutions in Mold Design for Gravity Cast Aluminum Parts

• Problem 1: Misrun and cold shuts in thick-walled aluminum parts - Solution: Optimize the mold's pouring system via CAE simulation, increase the cross-sectional area of sprue and runner to improve melt flow velocity; design a multi-point gating structure for large-sized thick-walled parts to ensure uniform filling; preheat the mold to 200-300℃ to avoid rapid cooling of aluminum melt; control the aluminum melt pouring temperature at 680-750℃ to enhance fluidity.

• Problem 2: Internal porosity and shrinkage cavities affecting structural strength - Solution: Optimize the mold's exhaust system, add exhaust ports and vents in gas-trapping areas (e.g., thick-walled corners) to discharge air and molten aluminum vapor; design risers in key thick-walled areas to supplement molten aluminum during solidification and compensate for shrinkage; adjust the pouring speed to avoid turbulent flow and air entrapment; select aluminum alloys with good fluidity and low gas content.

• Problem 3: Dimensional deviation of cast parts due to uneven cooling - Solution: Optimize the mold's cooling system layout, install cooling channels in areas with uneven wall thickness to ensure uniform cooling and solidification; select mold steel with good thermal conductivity and perform uniform heat treatment; adjust the demolding time according to the solidification state of aluminum parts; conduct multiple rounds of trial casting and dimensional calibration to ensure mold stability.

Frequently Asked Questions (FAQ)

• Q1: What types of gravity cast aluminum parts can your molds produce? - A1: Our molds can produce various gravity cast aluminum parts across industries, including automotive engine cylinder blocks, industrial gearbox housings, hydraulic pump bodies, valve bodies, new energy battery pack brackets, and medical equipment bases. We specialize in molds for thick-walled aluminum parts (wall thickness ≥5mm) and support customization based on client-specific drawings and performance requirements (e.g., load-bearing capacity, wear resistance).

• Q2: What is the lead time for custom molds for gravity cast aluminum parts? - A2: Lead time varies by mold complexity (part size, thick-walled structure, and cavity number): Sample molds take 12-22 working days, mass production molds take 28-55 working days, and urgent orders can be completed in 8-16 working days with an additional fee. The lead time is slightly longer than high-pressure die casting molds due to the need for precise design of the gravity casting pouring system. We will provide a detailed production schedule upon order confirmation.

• Q3: Do you provide quality assurance for your gravity cast aluminum part molds? - A3: Yes, we offer a 12-month quality guarantee for all molds for gravity cast aluminum parts. During the guarantee period, if quality issues arise due to mold design or manufacturing (e.g., dimensional deviation, mold leakage, casting defect recurrence), we will provide free repair or replacement services. We also offer lifelong technical support for mold maintenance and gravity casting parameter optimization.

• Q4: Can you provide one-stop services including production of finished gravity cast aluminum parts? - A4: Yes, we are equipped with 18+ professional gravity casting lines and a post-processing workshop. We can provide integrated one-stop services from mold design, fabrication to finished product gravity casting, machining, surface treatment, and assembly, which can effectively reduce your communication costs and shorten the production cycle.

• Q5: What certifications do your molds and finished gravity cast aluminum parts hold? - A5: Our factory is certified by ISO9001:2015 and IATF16949 (automotive industry quality management system). The aluminum alloys we use comply with ASTM and EN standards, and the finished gravity cast aluminum parts can pass industrial tests such as tensile strength, hardness, and corrosion resistance. We can provide relevant certification documents and test reports according to client requirements.

Product Classification & Technical Specifications

1. Product Classification by Industry, Material & Part Type

2. Technical Specification Parameters

Our Core Competitiveness

• 10+ Years of Gravity Cast Aluminum Expertise: Founded in 2012, we have focused on mold design and fabrication for gravity cast aluminum parts, serving over 200 clients from more than 40 countries, including Europe, North America, and Southeast Asia. Our profound experience enables us to accurately grasp the unique technical requirements of gravity casting and the quality standards of diverse global industries.

• Professional Technical Team: A team of 45+ engineers and technicians with an average of 8+ years of experience, proficient in gravity cast aluminum mold design, CAE simulation for low-pressure filling, and process optimization. They excel in solving complex technical issues such as thick-walled part forming, porosity control, and uniform cooling.

• Strong Production Capacity: Our 8,000-square-meter factory is equipped with 50+ sets of advanced production and testing equipment, including CNC milling machines, EDM machines, wire cutting machines, CMM, professional gravity casting lines, and X-ray flaw detectors. We have an annual production capacity of 100+ sets of gravity cast aluminum part molds.

• Strict Quality Management System: Certified by ISO9001:2015 and IATF16949, we implement full-process quality control from raw material inspection to finished product delivery. Our professional quality inspection team and complete testing equipment (corrosion test chambers, tensile testing machines, load-bearing test platforms) ensure product stability and compliance with international standards.

• Improved Supply Chain: We cooperate with reliable domestic suppliers to ensure stable supply and consistent quality of high-purity aluminum alloys and mold steel suitable for gravity casting. By integrating upstream and downstream resources, we achieve cost optimization and timely delivery, effectively supporting clients' medium-to-large batch production plans.

• Global Service Capabilities: Partnering with renowned international logistics companies (Maersk, COSCO), we leverage Qingdao Port's geographical advantage to provide efficient and safe global shipping. We offer 24-hour online technical support and a 12-month quality guarantee, promptly addressing after-sales issues for global clients.

Customer Case: Gravity Cast Aluminum Mold Project for North American Industrial Machinery Client

Our client is a leading industrial machinery manufacturer in the United States, specializing in hydraulic equipment production. They faced challenges with their original molds for gravity cast aluminum hydraulic pump bodies: serious misrun and cold shuts in thick-walled areas (wall thickness 15mm) led to low product qualification rate, and dimensional deviation (exceeding ±0.06mm) caused poor assembly with internal components. Additionally, the production cycle was long, affecting market supply. In 2023, they partnered with us to customize high-precision molds for their new-generation hydraulic pump bodies.

Our technical team first conducted a detailed analysis of the client’s hydraulic pump body drawings and performance requirements (tensile strength ≥230MPa, pressure resistance ≥15MPa, dimensional accuracy ±0.03mm). Using UG software, we built a 3D mold model and performed CAE gravity casting simulation to optimize the pouring system—adopting a multi-point gating design with 3 symmetric gates to ensure uniform filling of thick-walled areas, and adding 40 exhaust ports in gas-trapping corners. We selected H13 mold steel and designed a segmented cooling system to ensure uniform cooling and reduce thermal deformation. We also optimized the mold preheating process, setting the preheating temperature at 250℃ and pouring temperature at 720℃. During debugging, we conducted multiple rounds of trial casting and dimensional calibration to adjust process parameters.

The final delivered molds achieved outstanding results: The misrun and cold shut defects of the hydraulic pump bodies were completely eliminated, and the product qualification rate increased to 99.2%; the dimensional accuracy was controlled within ±0.03mm, ensuring seamless assembly with internal components; the production efficiency increased by 180% compared to the client's previous supplier, and the mold service life was guaranteed to exceed 1.2 million shots. The client highly recognized our product quality and technical expertise, signing a long-term cooperation agreement covering multiple industrial machinery component molds.

Why Choose Qingdao Xinlongji for Gravity Cast Aluminum Part Molds?

1.Professional Focus on Gravity Casting: We specialize in mold design and fabrication for gravity cast aluminum parts, with in-depth insights into gravity casting's process characteristics and aluminum alloy material properties, ensuring solutions that precisely match the forming needs of thick-walled and load-bearing aluminum components.

2. One-Stop Integrated Service: From mold design, fabrication to finished product gravity casting, machining, and assembly, we streamline the supply chain, reducing your communication and management costs. We also offer supporting processes for other casting and molding technologies to meet diversified demands.

3. Proven Technical Strength: Our advanced CAE simulation technology for gravity casting and professional engineering team effectively solve complex challenges (e.g., thick-walled part filling, porosity control), ensuring product quality and production efficiency.

4. Reliable Quality Assurance: International quality certifications and full-process quality control ensure our products meet global industrial standards, minimizing your production risks and facilitating your entry into international markets.

5. Efficient Global Support: With rich international trade experience and mature global logistics channels, we guarantee timely delivery of mold and finished product orders. Our 24-hour technical support team addresses after-sales concerns, providing peace of mind throughout your production process.

Qingdao Xinlongji Metal Manufacturing Co., Ltd. is committed to becoming a trusted partner in the global gravity cast aluminum part mold industry. We look forward to collaborating with you to create more reliable and efficient industrial aluminum components for the global market! For more information on our products and services, please feel free to contact us.