GLOBAL

Permanent Mold Solutions

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  • Date:2022/06/26

GSAL has the capability to manufacture valve components using our permanent mold aluminum casting process. Our permanent mold castings can produce porosity-free cast aluminum valve bodies for use in hydraulics, pumps, transmissions and other applications. Each step of our manufacturing process is carefully monitored and controlled to guarantee that your specifications are met. We use the latest technology to check the chemistry of our metal from start to finish. Computers are used extensively throughout the foundry.

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ADVANTAGES OF PERMANENT MOLD CASTING

1. Flexible Quantities

Another way,GSAL can meet your most demanding requirements is with flexible production quantities. The activity of some of the castings pictured above range from 250 pcs/yr to upwards of 100,000 pcs/yr.  Both are possible due to our innovative mold designs which skillfully balance tooling costs and unit costs.

2. High Strength

In our Permanent Mold Process, molten aluminum is poured into a metal mold that rapidly chills the aluminum. This causes the metal to solidify into a very fine-grain texture free of porosity and trapped gas. In turn, this gives our castings superior metallurgical properties, a high degree of pressure tightness, and a strength advantage greater than 15% over sand castings, alloy to alloy.

3. Less Machining

Machining is a costly operation. Our goal as manufacturing engineers is to minimize secondary machining and its costs by providing close dimensional control, a smooth finish, and total repeatability. Surfaces can be cast truly flat, sometimes even free from any draft or taper by suitable mold design. Time after time, switching from other processes to Permanent Mold has cut our customers' machining costs dramatically.

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4. Low Cost

Perhaps the greatest advantage of our castings is our competitiveness. Reducing machining gives our customers a low unit cost while tooling investments are minimized by our skilled engineering and mold shops. They use their years of experience and extensive knowledge to produce innovative mold designs that result in tooling costs often comparable to sand casting.

5. Molded Inserts

One of the most unique advantages of our Permanent Mold Process is the ability to cast molded inserts. As you can see, the casting above is cast with a stainless steel insert to provide an extra-hard, wear-resistant surface while keeping the rest of the part in lightweight aluminum. The casting with 4 brass threaded-hole inserts is designed to provide durable, wear-resistant threads. In high-volume situations, cast-in threaded inserts are sometimes even less expensive than CNC drilling or tapping. Either way, molded inserts are a very potent cost-saving technique available only through GSAL.

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6. Fine Surface Finish

Gaosheng castings have a finish that is fine and smooth enough for O-ring seals and gaskets in many applications. They are also smooth enough to be put against metallic surfaces in mating situations. In addition, our castings always have a clean, silvery appearance that minimizes the need for costly operations like polishing and mass finishing. Moreover, if need be, our castings also can be easily tumbled, painted, plated, anodized, e-coated, polished, and cast with crystal clear letters or logos. Try our Metal Finishing Center if the raw cast finish won't sell your product.

7. Close Tolerance

Our castings are made in metal molds so dimensional variation from piece to piece is negligible and close tolerance is consistently held. Our ability to achieve the highest accuracy and precision has allowed us to successfully cast many parts that have been used without machining, resulting in remarkable savings for our customers.

8. High Quality

Process control and upfront engineering are the keys to guaranteeing high-quality castings. This is probably why we exceeds the industry standards for internal scrap and failure rates. In summary, Gaosheng strives for Zero-Defects by continuously monitoring all processing and investing painstaking effort into tooling development and designs.

9. Complex Shapes

Our molds are machined out of blocks of high-grade steel. As evidenced by the casting above, complex shapes with thin walls can be cast using ingenious coring techniques so no machining is needed. Undercuts are routinely cast with the use of sand cores, and sometimes, even without.  Fully machined cavities, intricate coring techniques, and state-of-the-art molding make complex aluminum parts a routine task for GSAL.

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