- The mold can be reused
- The process can produce more complex shapes and designs (compare to sand casting)
- This process offers more precise control over dimensional attributes (compare to sand casting)
- Products have good as-cast surface finish (compare to sand casting)
- The process is highly repeatable and well-suited for high volume production runs
- The process can also be automated
- The process usually has less shrinkage or gas porosity issues
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Permanent Mould Gravity Casting
Omnidex Mining as an expert in Permanent Mold Gravity Casting has been producing quality Gravity Casting parts for the mining sector over many years. We are well-aware that a high level of skill is required to produce the high quality gravity castings demanded by the mining industry, and we always push for the highest quality standard to ensure our product is up to your expectation.
Our gravity casting process can produce parts with a smooth finish with all material specifications, dimensions and tolerances closely monitored and maintained. Just as the other casting processes we offer, we guarantee no porosity in our Gravity Casting parts. Learn more about our guarantee here.
What is different about Permanent Mold Gravity Casting
One of the oldest methods used for casting metals and alloys is permanent mold gravity casting. As its name suggests, the process involves molds that can be re-used many times, making this process ideal for mass production. While the production cost can be reduced for repeat projects, permanent mold gravity casting still sits between sand casting and die casting in terms of overall expense, with medium manufacturing and tooling costs. Check out our animation on how the process works:
Omnidex Permanent mold gravity Process Video
Permanent mold gravity casting has the following advantages:
The limitations and disadvantages of permanent mold gravity casting:
- Only materials with lower melting temperatures can be used in the process
- When materials with a high melting point (such as cast iron) is used, the high temperature may wear down the mold quickly
- Part geometry and size limited by die-making capability
- This process usually has higher tooling cost and longer set-up time
- Only economic viable for high volume production
Our Expertise in Permanent Mold Gravity Casting
We ensure smooth metal flow and minimal casting defects by pre-heating the casting mold to between 150°C (300°F) and 260°C (500°F). We then apply a ceramic coating to the mold cavities to extend the mold’s working life and make it easier to remove the casting parts.
A crucial part of the process is the pouring of molten metal. The mold is usually made of two halves of iron or steel tooling (male and female halves). Cores made from resin or sand can also be added to make hollow parts. The best materials for permanent mold gravity casting are non-ferrous alloys with lower melting points, including aluminium, zinc and copper alloys. Materials with a higher melting point are not recommended, as they may wear down the mold more quickly.
It is worth noting that if the pouring process is not done evenly, there may be flow marks visible on the finished parts. That is why we have our own casting specialists supervising the entire process, ensuring the molten metal is poured into the mold at just the right speed. After the casting is done, all sprues and runners are accurately trimmed, then cleaned and painted (if required) by an experienced crew of workers.
If you are looking to set-up a permanent mold gravity casting production, feel free to contact us. We can help you find the solution best-suited for your needs. Don’t forget to check out other casting processes on our website!
Get in touch with Omnidex Mining if you need more information or a quote.
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