{"id":8704,"date":"2026-09-01T15:14:25","date_gmt":"2026-09-01T15:14:25","guid":{"rendered":"https:\/\/partsmastery.com\/"},"modified":"2026-09-01T15:14:25","modified_gmt":"2026-09-01T15:14:25","slug":"aluminum-gravity-casting-a-complete-guide-from-process-to-selection","status":"publish","type":"post","link":"https:\/\/partsmastery.com\/fr\/aluminum-gravity-casting-a-complete-guide-from-process-to-selection\/","title":{"rendered":"Moulage par gravit\u00e9 de l'aluminium : guide complet, du proc\u00e9d\u00e9 au choix du mat\u00e9riau"},"content":{"rendered":"

<\/h1>\r\n\r\n\r\n\r\n
\"\"<\/figure>\r\n\r\n\r\n\r\n\r\nOnce you invest in a casting die, that cost becomes irreversible. Choosing the wrong process costs far more than a slightly higher unit price. It can lead to incomplete filling in thin-wall sections, surface blistering after T6 heat treatment due to trapped porosity, or unit costs that never drop even as production volume scales up. Aluminum gravity casting occupies a critical sweet spot in the process selection spectrum. This guide maps that boundary with hard data, explains where gravity casting outperforms high-pressure die casting, and provides a supplier checklist before you commit to tooling.\r\n\r\n\r\n\r\n\r\n

What Is Aluminum Gravity Casting?<\/h2>\r\n\r\n\r\n\r\n\r\nAluminum gravity casting is a permanent mold process. Molten aluminum is poured into a reusable steel or iron die cavity and fills entirely under gravitational force \u2014 no external pressure is applied. The mold is preheated and coated with a release agent before each cycle. Metal enters through a top pouring basin, and the casting is removed once it solidifies and cools.\r\n\r\n\r\n\r\n\r\n\r\nIndustry literature sometimes calls this process “aluminum gravity die casting” or “permanent mold casting.” All three terms refer to the same method. For context: low-pressure casting uses a pressurized riser to push metal upward through the gate, while high-pressure die casting injects metal at hundreds of bar. Gravity casting uses no pressurization at all \u2014 it relies solely on the static head of metal in the pouring basin.\r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\nCompared with sand casting, gravity casting’s metal die delivers consistent cavity dimensions cycle after cycle \u2014 no retooling is needed between runs. This repeatability places gravity casting between sand casting and high-pressure die casting in both cost and consistency.\r\n\r\n\r\n\r\n\r\n

How Aluminum Gravity Casting Works<\/h2>\r\n\r\n\r\n\r\n\r\nFrom molten aluminum to finished casting, the process breaks down into six steps:\r\n\r\n\r\n\r\n\r\n
    \r\n \t
  1. Mold preheating and coating.<\/strong> Heat the permanent die to 200\u2013300\u00b0C and spray a refractory release agent evenly. Mold temperature directly controls metal flow and skin formation speed.<\/li>\r\n \t
  2. Closing and clamping.<\/strong> Lock the two die halves together. Sand cores and metal inserts are pre-positioned to form internal cavities and undercuts.<\/li>\r\n \t
  3. Pouring and filling.<\/strong> An operator ladles molten aluminum into the top pouring basin. Fill speed depends on pour height and gating design, not a fixed machine cycle.<\/li>\r\n \t
  4. Solidification.<\/strong> Metal solidifies from the cavity wall inward. Risers feed solidification shrinkage to keep sections dense and shrinkage-free.<\/li>\r\n \t
  5. Die opening and ejection.<\/strong> The mold opens, and the casting drops by gravity or is pushed out by ejector pins.<\/li>\r\n \t
  6. Finishing and heat treatment.<\/strong> Remove runners and risers, then clean surfaces via shot blasting or tumbling. If the alloy supports it, apply T5 or T6 heat treatment to improve mechanical properties.<\/li>\r\n<\/ol>\r\n\r\n\r\n\r\n\r\nTilt pouring is a more stable alternative. The die rotates from horizontal to vertical during filling, so metal flows smoothly into the cavity with minimal turbulence and air entrapment. This method delivers more controlled directional solidification and reduces dependence on operator skill.\r\n\r\n\r\n\r\n\r\n\r\nGating and riser layout determine whether solidification shrinkage pulls toward the gate or toward the mold wall. This is the core design challenge in gravity casting \u2014 and exactly why a design for manufacturability (DFM) review before tooling pays for itself.\r\n\r\n\r\n\r\n\r\n

    Common Aluminum Alloys and Their Properties<\/h2>\r\n\r\n\r\n\r\n\r\nA356 is the workhorse alloy for structural gravity castings. After T6 heat treatment, its strength-to-weight ratio and ductility reach levels that sand casting and conventional die casting cannot match. Per EN 1706, A356-T6 test bars deliver a minimum tensile strength of 290 MPa, yield strength of 210 MPa, and elongation of 4%.\r\n\r\n\r\n\r\n\r\n
    \"\"<\/figure>\r\n\r\n\r\n\r\n\r\nOther alloys suit specific applications. A319 works well for engine and transmission housings where some hot cracking risk is acceptable. 6061 offers excellent weldability for frame structures that require post-cast joining. A380 is primarily a high-pressure die casting alloy, but it can also be used in permanent mold casting when part conditions allow.\r\n\r\n\r\n\r\n\r\n
    \r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n
    Alloy<\/strong><\/td>\r\nCastability & Shrinkage<\/strong><\/td>\r\nTraitable thermiquement<\/strong><\/td>\r\nApplications typiques<\/strong><\/td>\r\n<\/tr>\r\n
    A356 \/ A356-T6<\/td>\r\nExcellent fluidity, ~1.3% shrinkage<\/td>\r\nYes (T5\/T6)<\/td>\r\nStructural brackets, housings, wheels<\/td>\r\n<\/tr>\r\n
    A319<\/td>\r\nGood, some hot cracking risk<\/td>\r\nOui<\/td>\r\nEngine and transmission components<\/td>\r\n<\/tr>\r\n
    6061<\/td>\r\nModerate, excellent weldability<\/td>\r\nOui<\/td>\r\nFrames requiring post-weld strength<\/td>\r\n<\/tr>\r\n
    A380<\/td>\r\nFair in permanent mold<\/td>\r\nLimit\u00e9<\/td>\r\nGeneral housings, primarily HPDC<\/td>\r\n<\/tr>\r\n<\/tbody>\r\n<\/table>\r\n<\/figure>\r\n\r\n\r\n\r\n

    Design Limits and Process Parameters<\/h2>\r\n\r\n\r\n\r\n\r\nGravity casting has a stable but well-defined process window. The following industry-standard parameters define the boundary between as-cast blanks and finish-machined parts:\r\n\r\n\r\n\r\n\r\n
      \r\n \t
    • Dimensional tolerance:<\/strong> ISO 8062-3 DCTG 8\u201310. Approximately \u00b10.3\u20130.6 mm for the first 25 mm.<\/li>\r\n \t
    • \u00c9paisseur minimale de la paroi :<\/strong> 3\u20135 mm. Without pressure assist, metal skins over before filling thin sections.<\/li>\r\n \t
    • Surface roughness:<\/strong> As-cast Ra 1.6\u20136.3 \u00b5m.<\/li>\r\n \t
    • Machining allowance:<\/strong> 1.5\u20132.0 mm on faces requiring machining.<\/li>\r\n \t
    • Angle d'attaque :<\/strong> 0.5\u00b0\u20133\u00b0 on steel dies.<\/li>\r\n \t
    • Part weight:<\/strong> From a few grams up to approximately 50 kg.<\/li>\r\n<\/ul>\r\n\r\n\r\n\r\n\r\nWhen setting draft and machining allowances on A356 castings, reserve approximately 1.3% linear shrinkage. Otherwise, the casting envelope may exceed drawing tolerances before machining even begins. If as-cast dimensions cannot meet drawing requirements directly, secondary CNC machining can close the gap.\r\n\r\n\r\n\r\n\r\n

      Gravity Casting vs. High-Pressure Die Casting<\/h2>\r\n\r\n\r\n\r\n
      \"Thick-wall
      Thick-wall gravity casting (left) vs. thin-wall die casting (right)<\/figcaption><\/figure>\r\n\r\n\r\n\r\n\r\nBoth processes use permanent molds, but they solve different engineering problems. Base your selection on economics and part requirements, not habit. When a part needs to carry load after T6 heat treatment, or when production volume cannot justify high-pressure tooling costs, aluminum gravity casting is the better choice. It also avoids the gas entrapment common in thin-wall high-pressure parts \u2014 a problem that often limits subsequent heat treatment.\r\n\r\n\r\n\r\n\r\n
      \r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n
      Parameter<\/strong><\/td>\r\nGravity Casting<\/strong><\/td>\r\nMoulage sous haute pression<\/strong><\/td>\r\n<\/tr>\r\n
      Filling pressure<\/td>\r\nGravity head only<\/td>\r\n150\u20131200 bar<\/td>\r\n<\/tr>\r\n
      Tol\u00e9rance dimensionnelle<\/td>\r\nISO 8062-3 DCTG 8\u201310<\/td>\r\nDCTG 5\u20137, typically \u00b10.1 mm<\/td>\r\n<\/tr>\r\n
      \u00c9paisseur minimale de la paroi<\/td>\r\n3\u20135 mm<\/td>\r\n1.5\u20132 mm<\/td>\r\n<\/tr>\r\n
      Finition de surface<\/td>\r\nRa 1.6\u20136.3 \u00b5m<\/td>\r\nRa 0.8\u20133.2 \u00b5m<\/td>\r\n<\/tr>\r\n
      Economic volume<\/td>\r\n500\u201350,000 parts\/batch<\/td>\r\n50,000+ parts\/year<\/td>\r\n<\/tr>\r\n
      Co\u00fbt d'usinage<\/td>\r\nInf\u00e9rieur<\/td>\r\nPlus \u00e9lev\u00e9<\/td>\r\n<\/tr>\r\n
      Die life<\/td>\r\nLong<\/td>\r\nVery long, millions of cycles<\/td>\r\n<\/tr>\r\n
      Heat treatable<\/td>\r\nYes, low porosity<\/td>\r\nLimited, gas porosity risk<\/td>\r\n<\/tr>\r\n
      Internal density<\/td>\r\nDirectional solidification, low porosity<\/td>\r\nHigher unless vacuum-assisted<\/td>\r\n<\/tr>\r\n<\/tbody>\r\n<\/table>\r\n<\/figure>\r\n\r\n\r\n\r\n\r\nQuick pros and cons:\r\n\r\n\r\n\r\n\r\n
      \r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n\r\n
      Gravity Casting Advantages<\/strong><\/td>\r\nHPDC Advantages<\/strong><\/td>\r\n<\/tr>\r\n
      Better mechanical properties, low porosity<\/td>\r\nTighter tolerances, thinner walls<\/td>\r\n<\/tr>\r\n
      Heat treatable, refined grain structure<\/td>\r\nLower unit cost at high volume<\/td>\r\n<\/tr>\r\n
      Lower tooling investment<\/td>\r\nFaster cycles, higher throughput<\/td>\r\n<\/tr>\r\n
      Gravity Casting Limitations<\/strong><\/td>\r\nHPDC Limitations<\/strong><\/td>\r\n<\/tr>\r\n
      Thicker walls only<\/td>\r\nGas porosity, limited heat treatment<\/td>\r\n<\/tr>\r\n
      Slower cycles, medium throughput<\/td>\r\nHigher die cost<\/td>\r\n<\/tr>\r\n<\/tbody>\r\n<\/table>\r\n<\/figure>\r\n\r\n\r\n\r\n\r\nFor batches of only a few hundred parts, sand casting remains the most economical choice \u2014 even gravity tooling is hard to justify at that scale. Think of casting process selection as a three-step ladder: sand casting for prototypes and low volume, gravity casting for medium batches and heat-treated structural parts, and high-pressure die casting for mass-produced thin-wall components.\r\n\r\n\r\n\r\n\r\n

      When to Choose Aluminum Gravity Casting<\/h2>\r\n\r\n\r\n\r\n\r\nGravity casting is the right choice when most of the following conditions apply:\r\n\r\n\r\n\r\n\r\n
        \r\n \t
      • The part requires T6 heat treatment for strength and toughness.<\/li>\r\n \t
      • It is a structural or load-bearing component requiring internal soundness.<\/li>\r\n \t
      • Production volume falls in the medium range \u2014 roughly 500 to 50,000 parts per batch.<\/li>\r\n \t
      • Design wall thickness exceeds 3 mm.<\/li>\r\n \t
      • Tooling budget is limited and cannot absorb high-pressure die casting costs.<\/li>\r\n<\/ul>\r\n\r\n\r\n\r\n\r\nConversely, switch to high-pressure die casting when wall thickness is below 2 mm, annual volume reaches hundreds of thousands, tolerance requirements hit \u00b10.1 mm, or surfaces must be near-net-shape with no secondary machining allowed.\r\n\r\n\r\n\r\n\r\n

        How to Select a Gravity Casting Supplier<\/h2>\r\n\r\n\r\n\r\n\r\nBefore paying for tooling, evaluate aluminum gravity casting foundries across these six dimensions:\r\n\r\n\r\n\r\n\r\n
          \r\n \t
        1. In-house tooling capability.<\/strong> Foundries that design and machine their own dies have tighter control over lead times and revision cycles.<\/li>\r\n \t
        2. Alloy and heat treatment range.<\/strong> Confirm which grades they offer and whether T5\/T6 is done in-house or outsourced.<\/li>\r\n \t
        3. Inspection methods.<\/strong> Look for X-ray inspection of internal integrity, CMM for dimensional verification, and cast test bars for mechanical property validation.<\/li>\r\n \t
        4. Integrated post-processing.<\/strong> Completing machining, blasting, and surface finishing under one roof significantly shortens overall lead time.<\/li>\r\n \t
        5. Quality certifications.<\/strong> ISO 9001 is the baseline; automotive requires ISO 16949, and medical requires ISO 13485.<\/li>\r\n \t
        6. DFM feedback capability.<\/strong> A supplier that provides annotated drawing reviews before tooling can prevent first-article rejects.<\/li>\r\n<\/ol>\r\n\r\n\r\n\r\n\r\n\r\n

          PartsMastery Aluminum Gravity Casting Capabilities<\/h2>\r\n\r\n\r\n\r\n\r\nPartsMastery operates a certified casting network equipped with over 60 die casting machines, holding ISO 9001, ISO 16949, and ISO 13485 certifications. Our Shenzhen facility integrates tooling, casting, CNC machining, and surface finishing in one coordinated workflow \u2014 so gravity cast parts move from die to finished product without leaving the plant.\r\n\r\n\r\n\r\n\r\n\r\nAvailable aluminum grades include ADC10, A380, ADC12, pure aluminum, DM6, HA6, HA4, and 6063. Secondary CNC machining holds dimensional precision within \u00b10.01 mm.\r\n\r\n\r\n\r\n\r\n\r\n ","protected":false},"excerpt":{"rendered":"

          Once you invest in a casting die, that cost becomes irreversible. Choosing the wrong process costs far more than a slightly higher unit price. It can lead to incomplete filling in thin-wall sections, surface blistering after T6 heat treatment due to trapped porosity, or unit costs that never drop even as production volume scales up. […]<\/p>\n","protected":false},"author":3,"featured_media":8705,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[13],"tags":[710,709,713,712,711],"class_list":["post-8704","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-technical-blog-posts","tag-aluminum-casting","tag-aluminum-gravity-casting","tag-casting-process-selection","tag-gravity-die-casting","tag-permanent-mold-casting"],"blocksy_meta":[],"acf":[],"yoast_head":"\nAluminum Gravity Casting: A Complete Guide from Process to Selection -PartsMastery<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/partsmastery.com\/fr\/aluminum-gravity-casting-a-complete-guide-from-process-to-selection\/\" \/>\n<meta property=\"og:locale\" content=\"fr_FR\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Aluminum Gravity Casting: A Complete Guide from Process to Selection -PartsMastery\" \/>\n<meta property=\"og:description\" content=\"Once you invest in a casting die, that cost becomes irreversible. 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Choosing the wrong process costs far more than a slightly higher unit price. It can lead to incomplete filling in thin-wall sections, surface blistering after T6 heat treatment due to trapped porosity, or unit costs that never drop even as production volume scales up. 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