Gravity Die Casting

Albury Casting is a specialist gravity die caster and have been for the last 20 years through our Malaysian company, Megastra Jaya Sdn Bhd.

Among the many gravity presses both large and small is the Stahl tilt machine capable of taking dies up to 1300mm x 900mm. This machine is ideal for casting long drop castings as well as those castings where air entrapment is a problem.

Work done on this machine includes among other things, door panels, large fan blades and transmission housings.

In the tilt casting process the casting machine is tilted to a position where the joint line of the mould is horizontal (he die is laying horizontal) Metal is tipped into a “pouring bucket”, which pours into the runner system of the casting, and then the die is tilted 108 degrees to a position where the die is upright.
This movement through 108 degrees is done at a controlled rate, depending on the particular job,so the metal enters the casting cavity gently and with minimum air entrapment resulting in a clean casting surface and no gas porosity.

As well as this, since the casting is bottom filled the resultant progressive solidification eliminates shrinkage porosity in the casting. Although not suitable for all types of casting, it is certainly the best method for parts where surface finish and integrity are critical.

The range of gravity work, both static and tilt, covers large heat treated (T5) castings through to small pure aluminium electrical castings.

All aluminium ingot is purchased from ISO9002 registered suppliers and supplied with assay reports. As with the pressure castings. Albury Casting has the facilities to supply parts machined, powder coated and/or anodized either locally in Albury or in our Malaysian facility.

Pressure Die Casting

Pressure die casting is used where there is a need for a large number of dimensionally accurate, thin walled castings with an excellent surface finish. Pressure casting involves using force to “squirt” the aluminium into a design giving it higher accuracy. Repeatability, stability and speed are also added advantages as the hot die steel moulds are water cooled and hardened.

Typical pressure castings are compressor castings (conrods, heads, etc), fan blades & hubs and automotive parts (endcaps, brackets, housings, etc) These are but a few of the castings possible in pressure die-casting.

At Albury Casting we currently have 5 high pressure die casting machines to supply aluminium castings in the range of 100t – 650t (aluminium). As well as casting we also have finishing processes such as vibratory polishing, machining, powder coating and anodizing.

Currently all of Albury Casting’s pressure casting is being done in our Malaysian facility.