Gravity aluminum casting and injection casting: that's how we manufacture aluminum parts

The aluminum casting industry offers a wide range of options to produce high-quality and precise aluminum parts. Among the aluminum casting technologies, gravity aluminum casting and injection aluminum casting are the most common. Both offer unique advantages in the manufacturing of aluminum parts and are used in different applications, depending on the specific characteristics and needs of the project presented by the client. 

In this article, we focus on the gravity aluminium casting (GDC) and the injection aluminium casting (HPDC) methods. We discuss what they are, their advantages, and their main applications. Additionally, as a company specialized in casting aluminum parts in different alloys, we explain how you can entrust us with the task of shaping your projects. 
 

Stack of aluminum ingots

What is gravity aluminum casting?

Gravity aluminum casting, also known as shell casting, is a manufacturing process that uses gravity to fill a mold with a liquid aluminum alloy using a high-temperature-resistant ladle. In this way, cavity by cavity, the steel mold is filled with liquid aluminum at high temperatures, which can range from 600 to over 800 degrees Celsius. Then, the metal solidifies inside the mold. Once the metal has solidified, the fully molded aluminum piece is released. 

At Fundiciones Monfort, where we are experts in the gravity aluminium casting technique, we have automated this aluminum pouring process, cutting of runners, and surface finishing using belt conveyors, all done by robots. Therefore, each of the aluminum parts produced has the same optimal quality and detail, without exception. 

5 advantages of gravity aluminium casting 

1. Cost-saving: It involves lower tooling costs compared to other casting techniques. 
2. Dimensional accuracy: It offers the possibility of shaping aluminum parts with shapes that cannot be achieved with other casting techniques. 
3. Surface quality: The resulting parts have smooth and uniform surfaces without marks or defects, with excellent surface finishes. 
4. Production capacity: It is possible to produce both small and large parts. Additionally, gravity aluminum casting is an efficient way to produce large quantities of high-quality parts in series. 
5. Total automation possibility: Although it is usually a manual casting method, full automation of all processes is possible through the use of robots. 

Applications of gravity aluminium casting techniques

Gravity aluminium casting technology is typically used to produce aluminum parts with high technical requirements. These are some specific applications of gravity die casting: 

• Complex automotive aluminum parts: engine blocks, transmission covers, aluminum alloy wheels, towing hooks, etc.
• Components for energy transmission devices: components for solar panels, such as ferrules; components for wind turbines and combustion engines for generators.
• Industrial machinery components: parts for the food industry, structural components such as building facade panels, mechanisms and internal or external parts for industrial washers, ventilation system elements for buildings, tunnels, etc. 

This casting method is used in a wide range of industries where high-quality aluminum parts with specific characteristics are required. Therefore, the above applications are just some examples. 

What is injection aluminum casting? 

Injection aluminium casting, also known as die casting, is a manufacturing process in which high pressure is used to inject liquid metal (in this case, aluminum) into a mold to make parts with the desired shape. 

The high-pressure injection of liquid metal into a closed steel mold is achieved through a piston that moves thanks to a hydraulic system and pressurized gas. At the clamping end, a press holds a closed mold while absorbing the injection pressure and allowing the liquid aluminum to solidify. 

At Fundiciones Monfort, we also specialize in injection aluminium casting (HPDC). Through meticulous electronic control of the technique, we are able to guarantee high-quality finishes for our projects, achieving thinner and more complex aluminum parts without sacrificing excellent strength. 

6 advantages of injection aluminium casting

1. Short cycle time: the injection casting process is faster than gravity casting or shell casting, resulting in faster production cycles and greater production efficiency. 
2. Cost savings: money is saved both on the price itself and on the total cost of production and labor, due to the high efficiency and automation of the injection casting process. 
3. Precision in surface finishes: Pressure injection allows for complete mold filling and uniform and perfect material distribution, resulting in greater dimensional consistency and precision in surface finishes of the parts. 
4. Elaboration of complex shapes: the final result of the melted liquid metal molded by injection is an aluminum part of any shape or geometry, no matter how complex.
5. Reduction of part weight: in relation to the previous point, parts with thinner thicknesses than other casting techniques can be produced, thus considerably reducing the weight of the parts produced. 
6. Reduction of waste material: waste material is minimized due to its high precision and the ability to control the amount of material used in each part. 

Applications of injection aluminum casting

Injection aluminium casting is a popular method in the manufacturing of aluminum components. In the following points, we describe some of its most common applications. 

• Interior and exterior lighting fixtures: LED technology lighting supports, luminaires for highways, roads and urban areas, luminaire assemblies for industrial warehouses, stadiums and pavilions, etc. 
• Sanitary and cleaning equipment: aluminum components for medical diagnostic instrumentation, bed components for residences and hospitals, elements for hospital cleaning machinery, public common areas, dispensers, among others. 
• Urban and interior furniture: outdoor or public enclosure furniture, such as waste bins, benches, beacons. Also indoor furniture, such as tables, sofas, and chairs. 

Although this technique is used for many other cases, you can see that injection aluminum casting is a very efficient process that is used in a wide range of applications to produce precise parts with high mechanical strength and light weight. 

Monfort, experts in aluminum casting techniques

At Fundiciones Monfort, we are leaders in the European market for products made using the gravity aluminum casting method and the injection casting technique. In addition to offering solutions for aluminum component manufacturing for over 80 years, our professional experience has evolved and adapted to be at the forefront of aluminum casting technology. 

Our company dedicated to aluminum casting, therefore, has an important driving force with which we are able to achieve optimal solutions: innovation, both in technology and learning. In this way, we have robots that automate shell casting and pressure casting processes, as well as continuous technical training and learning for our employees. With this formula, we are able to manufacture aluminum parts, from the simplest to the most complex, and gain productivity, efficiency, and quality in our products. 

However, we not only focus on casting, but also participate in all other production processes: accompanying in the project definition process, engineering, mold design and manufacturing, and casting, in gravity or injection, as well as machining operations and surface finishing. 

The use of one casting technique or another will depend on the type of project presented by the client. If you are looking for an experienced partner in the most reliable aluminum casting techniques, at Fundiciones Monfort we will advise and offer you a wide range of aluminum solutions and products. In addition, if you need to consult any kind of doubt or inquiry about the production of your project, you can do so through the form we leave just below. We are eager to help you, so let's get to work!