Gravity Die Casting Process for Manufacturing Aluminum Alloy Casting Wheel

The popularity of casting wheels is growing rapidly, making them one of the best choices for two-wheelers and four-wheelers. The Gravity Die Casting process used to manufacture a casting wheel has multifarious benefits to the automotive industry.

The advantage of using aluminum alloy

Aluminium alloy is considered the best raw material for casting wheels used in the automotive industry.

• The strength-to-weight ratio of aluminum alloys is much better than steel, making the alloys the best choice for casting wheels.
• Aluminum alloy has an excellent thermal conductivity that helps in dissipating heat generated during breaking quickly.
• Aluminium is corrosion-resistant by nature which makes the alloy wheels long-lasting even in adverse weather conditions.
• The lightweight of aluminium alloys lowers the weight of the vehicles bringing loads of advantages like better fuel efficiency and better control over the vehicles.

Gravity Die casting (GDC) process

The gravity die-casting process is one of the most used manufacturing processes for manufacturing aluminum alloy wheels. In this process, molten aluminum is poured into a reusable steel or cast iron mold called a die under the force of gravity. The gravity die-casting process is well suited for casting wheels with aluminum alloy since all parts can be produced with low porosity, consistent quality, and desirable mechanical properties.

Steps involved in the gravity die-casting process for manufacturing casting wheel

In the gravity die-casting process, several steps are involved in manufacturing high-quality and defect-free aluminum wheels. The breakdown of each of those steps is listed as follows:

• Preparation of die and pre-heating: The die is prepared by cleaning and applying a lubricant layer or releasing agent. This layer helps in releasing the wheels smoothly from the mold once it becomes solidified. The die is also pre-heated so that the cooling of the alloy becomes uniform and the thermal shock is minimized which will otherwise will affect the longevity of the alloy and the quality of the casting will also be compromised.
• Melting the aluminum alloy: In the aluminum alloy, there is a blend that contains some elements like silicon and magnesium. These elements are melted at a high temperature. Aluminum alloy is useful for wheels because of its lightweight and resistance to corrosion properties.
• Pouring the molten metal: The molten aluminum is then poured into the mold cavity very carefully. In the process of gravity-die casting, the metal fills the mold naturally due to the influence of gravity instead of providing external pressure. To prevent turbulence the speed of pouring the molten metal is also controlled which helps in reducing air bubbles and porosity in the casting.
• Cooling and solidification: Once the aluminum alloy is poured it gets cool gradually and solidifies itself within the mold. The process of cooling is very important since it can affect the final strength and graining of the structure of the casting wheel. In some molds, there are built-in cooling channels that help regulate the rate of cooling and ensure consistency across each casting.
• Ejection and Finishing: When the casting wheel gets completely solidified it is ejected from the mold very carefully to prevent any kind of damage. For removing the excess material and achieving precise dimensions of the wheel post-casting finishing processes such as trimming, debarring, and machining are applied. Moreover, surface treatments such as polishing and powder coating are also applied to make the wheel smooth and aesthetically pleasing finish.

The gravity-die casting process is a reliable and efficient method for casting high-quality aluminum alloy wheels. With numerous benefits such as enhanced structural integrity, precise dimensional control, and cost-effectiveness this process of manufacturing wheels is getting popular day-by-day. Again, with more advancement, this process of manufacturing casting wheels becomes more versatile and efficient and certainly ensures its place in future wheel manufacturing processes.