Casting Process

Casting Process - Gravity Die Casting (GDC)

At Gescons (1961) Private Limited, we specialize in gravity die casting (GDC) of aluminium alloy components, delivering durable, dimensionally accurate, and high-performance castings tailored to industry needs.

With over six decades of experience, we have developed a streamlined, quality-focused GDC process supported by modern infrastructure and in-house machining capabilities.

Our GDC Manufacturing Process
  • 1Die Preparations

    High-grade steel dies are pre-heated and coated with release agents for smooth casting and longer tool life

  • 2Melting & Alloying

    Aluminium alloys are melted in crucible furnaces and analyzed using our in-house spectrometer to ensure composition accuracy.

  • 3Gravity Pouring

    Molten aluminium is poured into the die purely by gravity, resulting in dense, high-integrity castings with minimal porosity.

  • 4Solidification & Ejection

    After controlled cooling, the cast part is ejected and sent for post-processing.

  • 5Trimming & Fettling

    Runners, risers, and flashes are removed. Components are fettled and prepared for heat treatment.

  • 6Heat Treatment

    Components undergo ageing or other thermal treatments to improve strength, hardness, and dimensional stability based on application needs.

  • 7Shot Blasting

    Heat-treated parts are shot blasted to clean the surface, remove scale, and create a uniform finish suitable for machining or coating.

  • 8In-House Machining

    Precision CNC and VMC machining is performed in-house to achieve required dimensions, tolerances, and surface finishes.

  • 9Leak Testing & Inspection

    Castings are tested using a helium leak detector with vacuum chamber (if required), along with CMM inspection, hardness, and metallurgical checks.

Our Strengths in GDC

Casting weight range: 0.5 kg to 100 kg.

Alloys used: LM6, LM24, ADC12, as per application

High repeatability for batch production

In-house quality lab with spectrometer, microstructure, hardness tester

Flexible for low- to medium-volume production

Applications We Serve

Motor housings

Gearbox covers

Medical Suspension Brackets

Control brackets

Structural aluminium parts

Why Gescons for GDC?

60+ years of foundry experience

Fully in-house operations: casting to CNC to inspection

Next-Gen Aluminium Casting Ecosystem

Quick prototyping and technical support

Pan-India delivery from our Kolkata facility