WHAT IS VACUUM DIE CASTNG?
Porosity is a predominant issue in any traditional die casting process. It severely affects the casting integrity, thus compromises the quality and performance. So, a vacuum system is utilized in a pressure die casting process to avoid this as much as possible. It is known as vacuum-assisted high pressure die casting, or in short, vacuum die casting.
The complete vacuum casting process is similar to any regular die casting process, with the exception of creating a vacuum in the die cavity before casting. Here is a step by step guide below:
- Firstly, melt the metal that you need for casting.
- Now, use the vacuum pump to create a vacuum in the die cavity.
- Then add pressure to the molten metal to inject it into the cavity.
- After that, wait for the part to solidify and cool down.
- Finally, eject the part from the die.
Advantages of Vacuum Die Casting
Vacuum die cast has some benefits, which is why manufacturers all over the world prefer this process nowadays. For example:
- You can reduce surface defects like blowholes and blisters with the vacuum casting process.
- Vacuum die cast can nearly eliminate the chances of having any porosity in casting.
- As there is negative pressure in the cavity due to vacuum, the molten metal can easily reach all the recesses. Therefore, it allows you to cast thinner and more precise parts.
- Vacuum die cast parts are denser and have higher mechanical strength than others.
- You will need to perform fewer post-production operations as it greatly reduces the casting defects and yields parts with an excellent surface finish.
- The porosity in casting renders them suitable heat treatment. But vacuum die cast parts have negligible gas pores, thus ideal for heat treatment.
Sunrise Metal – One of the Best Vacuum Casting Manufacturers in China
Sunrise metal is one of the topmost professional vacuum casting manufacturers in China. We provide the best vacuum die cast service for you to achieve more precise and accurate parts.
We manufacture parts that are used in the Medical, Telecommunications, Automotive, and Networking industries. Aluminum alloys are used to produce high-quality and lightweight parts.
Vacuum Casting System
In Sunrise Metal, we use the DIEVS200-CVC2 vacuum casting system, which we have imported from Japan. We can create pore-free casting with the equipment. Therefore, we can ensure better structural integrity and surface finishing for our parts.
Precise Quality Control
We always perform a strict and thorough inspection of all the parts before the final shipping. Our quality testing labs are equipped with sophisticated measuring instruments. Our quality control experts thoroughly check your parts to ensure the highest quality and precision for all parts.
Advanced Tools & Machines
We have advanced tools and machines which are capable of
- 3D Printing
- Multi-axis CNC Prototyping
- Plating, Anodizing, Polishing
- Die Casting Mold
- Grinding, Drilling, Turning, Milling, etc.
We combine our vacuum die cast process with these technologies to achieve better results in parts manufacturing.
ISO 9001 & IATF 16949 Certification
Sunrise metal is ISO 9001 and IATF 16949 certified, which signifies our product’s high-quality standard and promotes our corporate efficiency. Our employees are always aware of the quality, and we always satisfy our customers with our service.
We are always working on improving our service day by day. Preventing defects in products and reducing manufacturing wastes is also our priority.
Which Industries Require Vacuum Die Casting Parts?
Most of the industries which deal with metal die casting parts requires vacuum die cast. Because vacuum die casting parts are more precise, denser, and of higher quality. Below is a list of industries that desire vacuum die cast parts:
- Aerospace (wings, brackets, windshields, engine components, etc.)
- Marine (radar housing, pump housing, heat sinks, etc.)
- Telecommunication (front faceplates, antenna mounts, RF filters, etc.)
- Automobile (cylinder heads, stators, motor covers, heat sinks, etc.)
- Electronics (traffic lights, fan blades, etc.)
- Military (trigger guards, triggers, safeties, etc.)
- Medical (gearboxes, peristaltic pumps, surgical tools, etc.)
It is just the tip of the iceberg of the parts which require vacuum die casting. There are many more potential applications for vacuum die cast parts out there.
How is Vacuum Die Casting Cheaper?
The vacuum die cast process is similar to any regular die casting. But, you need to install an additional vacuum mechanism in case of vacuum die cast. In this process, this pump is mounted on the die cavity. Installing the pump requires additional expenses. That is why most people think that vacuum die cast is more expensive than normal die casting.
But in reality, vacuum die cast is both cheaper and faster in the long run. Because the vacuum die cast parts have very low porosity. This results in higher density and stronger mechanical properties for the parts. That is why there are fewer post-processing operations involved in vacuum die cast.
The vacuum generated by the pump creates negative pressure in the cavity. So the molten metal reaches every corner of the cavity more precisely. That’s why the surface finishing is better in this process. Such surface finish doesn’t require too much post-processing and saves the time of machining.
Though there is an initial cost for installing the pump, the cost of post-process machining reduces vastly in vacuum die casting. That’s why, in a broad sense, this process is cheaper.
Which Defects can Vacuum Die Casting Reduce?
In die casting, the common defects are:
When small bubbles of air/gas are trapped inside the cavity, it results in porosity. If there is too much porosity within the part, it loses its strength. That is why porosity is one of the worst defects in die casting.
Misrun is the defect that occurs because of the failure of the molten metal to fill up the cavity properly. Therefore, it results in defective casting, which you have to discard and cast again. Consequently, it results in a waste of production time and effort, which in turn increases the production cost.
Blisters mostly occur during or after heat treating the parts. It occurs due to the entrapped gas or air inside the metal parts after solidification. Blisters can cause uneven surface finish in your parts.
When the molten metal enters the cavity from two different holes, it fails to merge properly sometimes. In this case, a void space occurs. This is cold shuts. Cold shuts make the parts weak and fragile.
Vacuum die casting can greatly reduce or eliminate most of the common die casting defects. Therefore, it can substantially increase the casting quality and reduces unnecessary post-processing operations.