51 Lathams Rd

Carrum Downs VIC 3201

Gravity, Low Pressure & Sand Aluminium Castings

Case Studies

Barrier group

Customer: Barrier Group

Product:

ZEPHYR BIKE STORAGE BOLLARD

Market: 

Local/export – architectural
Designed and manufactured in Australia

Gravity Die Casting New Zealand

Product Information:

  • In a busy city 'Zephyr' is a stunning short or long term bicycle storage solution.
  • Part weight: 18kg
  • Aluminium: Cast AA6061 grade aluminium
  • Size: 845mm high x 224mm wide x 394mm deep
Low Pressure Die Casting New Zealand

Processes:

  • Tilt gravity casting 
  • Fettle runners and overflow and all parting line scars
  • Cosmetic polish
  • Pack and dispatch
Sand Casting New Zealand

Technical Challenges:

  • The Zephyr Bike bollard is a one piece design with complex geometries
  • Due to the complex geometries of the part, the tooling was manufactured with two movable sliding cores. The product was also tilted on a angle to allow for the part to extract from tool
Casting Porosity Sealing & Impregnation New Zealand

100% Australian designed and manufactured from Australian aluminium!

Casting Porosity Sealing & Impregnation Australia
Aluminium Die Casting Australia

Imaxeon

Customer: Imaxeon Pty Ltd

Product:

IMAC61 Arm and IMHCO1 Base Casting

Market: 

Local – medical

Gravity Die Casting New Zealand

Product Information:

  • Aluminium cast arm and base components for contrast injection system
  • Arm casting – part weight: 1.08 kg
  • Base casting – part weight: 6.70 kg
  • Aluminium: cast CA401 grade aluminium

Processes:

  • (Base casting) – tilt gravity casting (over-molding 4 x thread inserts)
  • (Arm casting) – stationary gravity casting fettle runners and overflow and linish all parting line 
  • CNC machine
  • Powder-coat 'Mannex Silver', 'Graphite Ripple' pack and dispatch
Low Pressure Die Casting New Zealand

Technical challenges:

Base Casting:

Complex geometry with multiple shutoffs within the gravity tool.

Arm Casting:

The cast arm is highly visible and requires a high level of surface preparation prior to applying the powder-coat finish.

High tolerance CNC machining including fitting a bronze bush.

Radio Frequency System (RFS)

Customer: RFS – Radio Frequency Systems

Product:

6PPXX160E filter body casting

Market: 

Local/export – telecommunication

Product Information:

  • Filter body casting.
  • Part weight: 19.5kg
  • Aluminium: cast AA601 grade aluminium 
  • Size: 533mm high x 337mm wide x 204mm deep

Processes:

  • Tilt gravity casting 
  • Fettle runners and overflow and all parting line scars
  • Heat treat T5
  • Pack and dispatch
Gravity Die Casting New Zealand

Technical Challenges:

The part has very deep pockets (male form) on both fixed and moving sides of the tool.

Casting Porosity Sealing & Impregnation New Zealand

Hycast metals

Customer: Hycast Metals/Hong Kong Jockey Club

Project: Hong Kong Central Police Station Conservation and Revitalisation Project.

The Central Police Station Revitalisation Project is an important initiative to conserve and revitalise the heritage site comprising the Central Police Station, the Central Magistracy and the Victoria Prison for adaptive reuse.

The new Landmark Art Gallery will comprise of an external steel frame with an innovative façade made from aluminium bricks that mimic the existing brick patterns on site.

Melbourne Gravity in partnership with Hycast Metals is successfully manufacturing and supplying the innovative façade made from cast aluminium.

Market: 

Export – Architectural

Product Information:

  • Aluminium façade casting with granite surface texture
  • Part weight: 55kg
  • Aluminium: cast DA601 grade aluminium
  • Size: 471mm high x 1177mm wide x 273mm deep

The aluminium façade casting has a unique detailed surface texture which required the tool to be designed in such a way that the product would freely extract from the diecasting tool.  The product design was initially conceived to be impossible to manufacture using the low pressure casting process due to the textured surface finish.

Gravity Die Casting New Zealand

Before the project even started a trial die was produced to replicate the surface texture (1) to evaluate the surface texture within the casting process and (2) to trial an approved finish on the Cast DA601 grade aluminium diecast alloy. The Initial trials proved successful, so much so that the project was able to move to the next stage: product design/tool design.

Casting Porosity Sealing & Impregnation Melbourne

Product Design/Tool Design – Designed for Manufacturing:

By applying the lessons learnt from the trail tools, we were able to merge the granite texture into a 3D model to represent the finished product. By completing the 3D model and having a true representation of the finish product, we were then able to determine the optimum choice for feeding the part, tool layout to include 4 different variants, and location of the thermal channels for production performance.

Working closely with the great team at Unimold (Italy), Melbourne Gravity/Hycast Metals was able to design a generic tool to manufacture the 4 variants of bricks required.

The tool was designed with 4 common sliding cores and 4 different sets of fixed and moving inserts.

Careful consideration was given to the tool design and the method in which to produce a quality casting.

To ensure the casting was produced the first time from the tool, a total of 30 flow and thermal simulations were undertaken to determine the best feeding method and optimum thermal control required. The number of simulations was a true reflection of the difficulties in producing this casting. Typically an average casting would only require 4-5  simulations.

Low Pressure Die Casting Melbourne
Low Pressure Die Casting Australia

Processes:

Melbourne Gravity:

  • Low pressure casting
  • Pack and dispatch
  • Fettle runners and overflow and all parting line scars
  • Heat treat

HyCast Metals:

  • CNC Machine
  • Approved finishing
  • Pack and dispatch

Liquip

Customer: Liquip International

Product:

  • 400mm (16") MANHOLE COVER

Market:

  • Local/export – oil and gas

Product Information:

  • MANHOLE COVER. Ø400mm (16")
  • Part weight: ------kg  assembly
  • Aluminium: cast AA6061 grade aluminium

Processes:

  • Low pressure gravity casting
  • Fettle over flows and runners
  • CNC machine
  • Handwork to clear machining burrs
  • Pack and dispatch as case and lid set

Product:

  • SLV5-ARO Emergency Valve with Sequential Actuator

Market:

  • Local/export – oil and gas.

Product Information:

  • Emergency Valve
  • Part weight: ------kg
  • Aluminium: cast AA6061 grade aluminium

Technical Challenges:

  • Multiple sliding cores within the tool to form external geometry of the casting
  • Disposable sand core to form internal undercuts within the product.

Processes:

  • Stationary gravity casting (over-molding disposable sand core)
  • Fettle runners and overflow
  • Remove disposable sand core
  • Heat treat T6
  • CNC machine
  • Handwork to clear machining burrs
  • Vacuum impregnate
  • Pack and dispatch

Product:

  • API Outlet Adaptors

Market:

  • Local/export – oil and gas

Product Information:

  • Outlet adaptors.
  • Part weight: ------kg,
  • Aluminium: cast AA6061 grade aluminium

Processes:

  • Stationary Gravity casting
  • Fettle runners and overflow
  • Heat treat T6
  • CNC machine
  • Handwork to clear machining burrs
  • Vacuum impregnate
  • Pack and dispatch
Aluminium Die Casting Australia

Product:

  • AVV075V with Sequencing Valve Built-In

Product Information:

  • Vapour vent
  • Part weight: ------kg
  • Aluminium: cast AA6061 grade aluminium

Market:

  • Local/export – oil and gas

Processes:

  • Stationary gravity casting (over-molding disposable sand core)
  • Fettle runners and overflow
  • Remove disposable sand core
  • Vacuum impregnate
  • Heat treat T6
  • CNC machine
  • Handwork to clear machining burrs
  • Pack and dispatch
Aluminium Die Casting Melbourne
Aluminium Die Casting New Zealand

Technical Challenges:

Over-molding of disposable sand core to form internal undercuts within the casting process.

Product:

  • RS400 – Roll-Over Sensor

Product Information:

  • Roll-Over Sensor Lid and Base
  • Part weight: ------kg
  • Aluminium: cast AA6061 grade aluminium

Processes:

  • Stationary gravity casting
  • Fettle runners and overflow
  • CNC machine
  • Handwork to clear machining burrs
  • Pack and dispatch

Market:

  • Local/export – oil and gas

Aluminium Die Casting Australia

Product:

  • API710 automatic latching bottom loading coupler

Product Information:

  • loading coupler
  • Part weight: ------kg
  • Aluminium: cast AA6061 grade aluminium

Processes:

  • Stationary gravity casting
  • Fettle runners and overflow
  • CNC machine
  • Handwork to clear machining burrs
  • Vacuum impregnate
  • Pack and dispatch

Market:

  • Local/export – oil and gas

Technical Challenges:

Multiple sliding cores within the tool to form external geometry of the casting

Aluminium Die Casting Melbourne

Liquip specialise in the design, development and manufacturing of premium quality equipment for the bulk handling of fuels and related chemicals.