04-21-2021, 02:03 AM
Vacuum Die Casting
YI HITECH is a rich experienced die casting manufacturer with vacuum die casting in china. Although traditional equipment and processes have been greatly improved in recent years, it does not mean that good equipment plus higher education talents will definitely produce the best quality products. With vacuum die casting technology application and professionalism, YI HITECH will provide you best solution for your die casting project. We are willing to use our years of successful experience to contribute our modest efforts to the development of die-casting project.
What is vacuum die casting?
Vacuum die-casting is an advanced die-casting process that improves the mechanical properties and surface quality of die-casting parts by removing completely or reducing significantly the pores inside of die-casting parts through extracting the air in the die-casting mold cavity prior to injection of the molten metal with an equipment of vacuum device during the die-casting process. Vacuum die casting is a unique type of complex casting process for production of higher quality surface finish, improved mechanical properties and high-end product which may require minimal post-production machining and coating, that is characterized by forcing molten metal under high pressure into a mold cavity, where it is held by a powerful press until the metal solidifies. It is most commonly used at aluminum, zinc, magnesium, of product. Recently, vacuum die casting become more and more popular, that mainly used to remove the gas from the cavity. There are two main forms:
(1) Extract air directly from the mold cavity.
(2) Place the mold in a vacuum box to extract air. When using vacuum aluminum alloy die casting, the design of the exhaust duct location and exhaust duct area of the mold is very important. There is a "critical area" in the exhaust duct, which is related to the amount of gas extracted in the cavity, the extraction time and the filling time. When the area of the exhaust duct is larger than the critical area, the vacuum aluminum alloy die casting effect is obvious; otherwise, it is not obvious.
The choice of vacuum system is also very important. It is required that the vacuum in the cavity can be maintained until the filling is completed before the vacuum pump is turned off. Oxygenated die casting technology the gas in the pores of the die casting is mostly N2 and H2, and there is almost no O2. The main reason is that O2 reacts with active metals to form solid oxides, which provides a theoretical basis for oxygenated die casting technology. Oxygen-filled die-casting is to fill the cavity with oxygen before die-casting to replace the air in it.
Because pressure casting completes the filling process in a very short time, it is easy to cause gas to be involved and affect the quality of the die casting. To this end, oxygen-added die-casting machines and vacuum die-casting machines have been developed, and medium-pressure die-casting machines have also developed rapidly. Some die-casting machines have a tilting mechanism for the clamping mechanism. Die-casting process automation and die-casting computer control and die-casting flexible machining units (FMC) have also been gradually developed.
(1) Oxygenated pressure casting is to fill the pressure chamber and cavity with oxygen before filling the cavity with aluminum metal liquid to replace the air and other gases in it. Its characteristics are: eliminating or reducing air holes and improving the quality of castings; simple structure, convenient operation and low investment.
(2) In vacuum pressure casting, the air in the die-casting cavity is evacuated first, and then the liquid metal is pressed. Its characteristics are: it can eliminate or reduce the pores in the die casting, improve the mechanical properties and surface quality of the casting; greatly reduce the back pressure of the cavity during die casting, and can use lower specific pressure and alloy with poor casting performance
Conventional Die Casting VS Vacuum Die Casting Products
Comparison of metallographic structure between ordinary die casting and vacuum die casting (50 times)
Oridinary die casting with vacuum die casting
How vacuum die casting works
Vacuum die casting involves a steel die equipped with a vacuum valve at the top of die that connected vacuum pump device aside, a casting machine. Molten metal enters the die while vacuum pump starts to work and control by vacuum valve, creating a pressure differential between the die cavity and the molten metal in the crucible. This pressure differential causes the molten metal to flow up the sprue and into the die cavity, where it solidifies. The die is opened, and the casting parts is ejected. The cycle is then repeated with each shot producing from one to several castings, depending on the number of cavities in the die.
Key vacuum casting process elements
Factors affecting the following aspects of vacuum die casting. The design and manufacturing of the vacuum die casting mold process is the key to determining the quality of the casting.
1. Due to the very large clamping force of the die casting machine, the mold parting surface is prone to stress and deformation after extrusion. The flatness and tightness of the mold processing have very high requirements.
2. The control of the air leakage phenomena such as the side clearance of the mold row slider, the clearance between the thimble and the melting cup gate sleeve will directly affect the effect of high vacuum pumping
3. Melting technology: control of indicators such as degassing, slag removal and hydrogen content;
4. Setting of process parameters of die-casting equipment, etc.
5. Mould and vacuum component maintenance frequency
6. Vacuum level in die cavity is less than 50 millibar
7. Special die sealing (cavity, plunger tip, all inserts, ejector pins)
8. Vacuum die components for sealing
9. Control system for die temperature.
10. Die lube spray program control
11. Advanced process monitoring and control system.
12. W3 alloy (ductile)
Advantages Of Vacuum Die Casting
1) Mitigate or remove burning marks on the casting part.
2) Improve shrink marks by enhance cavity filling
3) Improved static, mechanic and dynamic properties
4) Vacuum casting can improve heat treatment of die cast part.
5) Vacuum die casting can improve weldability for cast parts.
6) Vacuum die casting can eliminate or reduce porosities inside the die casting,
7) Improve the mechanical properties and surface quality of the die casting,
8) Improve casting part plating performance.
9) The vacuum die-casting method greatly reduces the back pressure of the cavity, It can use a lower specific pressure, and it is possible to die-cast a larger casting with a small machine
10) The vacuum die-casting improves the filling conditions to cast thinner parts.
11) Compared with the ordinary die casting, the vacuum die casting has almost the same production efficiency.
12) Reduced injection pressure and gate speed
13) Extend tool service life
Disadvantages of vacuum die casting
1) The mold sealing structure is complicated than ordinary casting, it is challenging to making and installing, so the cost is high.
2) It is challenging for the process control of vacuum casting, if it out of control, the result will not obvious.
Application scope of vacuum die casting
1. High-strength structural parts
2. Airtight parts
3. Auto parts
4. Communication filter
5. Pure aluminum / alumina parts
6. Plating parts
7. Power tools
8. Other high-quality die-casting parts
FAQ
Q: Does samples available before order?
A: Yes, if it is the stock product, the sample can be sent for free in 3 days, if customized, will be sent within 7 days.
Q: How about the sample policy?
A: We can provide free sample if the raw material is cheap. However, you have to pay the cost of courier by express like: DHL, TNT, UPS and FEDEX.
Q: Can you make my designs?
A: Yes, OEM/ODM is welcome, pls feel free to send us pictures. If necessary, we can keep your design be protected under law.we will sign NDA with you.
Q: Can I place mix order?
A: Yes, you can mix colour and style in our stock items.
Q: Can I get discounts?
A: Yes, for big order, old customer and frequent customers, we give reasonable discounts.
Q: Which Shipment way is available?
A: By sea to your nearest port. By air to your nearest airport. By express (DHL, UPS, FEDEX, TNT, EMS) to your door.
Q: What is the payment method?
A: We accept TT (Bank Transfer), Western Union, L/C, Paypal.
1. For total amount under US$500, 100% in advance.
2. For total amount above US$500, 30% in advance, the rest before shipment.
Q: What is the quality of your product?
A: We specialized in high quality products, we have rich experience in manufacturering.
Q: what is your core competence?
A: we have advance software to simulate and give you constrictive solution for your project, especially, we prefer to challenge part. We鈥檇 like low volume and high mix prats.
Q: Can you make casting according to our drawing?
A: Yes, we can make casting according to your drawing, 2D drawing, or 3D cad model. If the 3D cad model can be supplied, the development of the tooling can be more efficient. But without 3D, based on 2D drawing we can still make the samples properly approved.
Vacuum Application StudyDie Casting factory
website:http://www.yi-hitech.com/die-casting/
YI HITECH is a rich experienced die casting manufacturer with vacuum die casting in china. Although traditional equipment and processes have been greatly improved in recent years, it does not mean that good equipment plus higher education talents will definitely produce the best quality products. With vacuum die casting technology application and professionalism, YI HITECH will provide you best solution for your die casting project. We are willing to use our years of successful experience to contribute our modest efforts to the development of die-casting project.
What is vacuum die casting?
Vacuum die-casting is an advanced die-casting process that improves the mechanical properties and surface quality of die-casting parts by removing completely or reducing significantly the pores inside of die-casting parts through extracting the air in the die-casting mold cavity prior to injection of the molten metal with an equipment of vacuum device during the die-casting process. Vacuum die casting is a unique type of complex casting process for production of higher quality surface finish, improved mechanical properties and high-end product which may require minimal post-production machining and coating, that is characterized by forcing molten metal under high pressure into a mold cavity, where it is held by a powerful press until the metal solidifies. It is most commonly used at aluminum, zinc, magnesium, of product. Recently, vacuum die casting become more and more popular, that mainly used to remove the gas from the cavity. There are two main forms:
(1) Extract air directly from the mold cavity.
(2) Place the mold in a vacuum box to extract air. When using vacuum aluminum alloy die casting, the design of the exhaust duct location and exhaust duct area of the mold is very important. There is a "critical area" in the exhaust duct, which is related to the amount of gas extracted in the cavity, the extraction time and the filling time. When the area of the exhaust duct is larger than the critical area, the vacuum aluminum alloy die casting effect is obvious; otherwise, it is not obvious.
The choice of vacuum system is also very important. It is required that the vacuum in the cavity can be maintained until the filling is completed before the vacuum pump is turned off. Oxygenated die casting technology the gas in the pores of the die casting is mostly N2 and H2, and there is almost no O2. The main reason is that O2 reacts with active metals to form solid oxides, which provides a theoretical basis for oxygenated die casting technology. Oxygen-filled die-casting is to fill the cavity with oxygen before die-casting to replace the air in it.
Because pressure casting completes the filling process in a very short time, it is easy to cause gas to be involved and affect the quality of the die casting. To this end, oxygen-added die-casting machines and vacuum die-casting machines have been developed, and medium-pressure die-casting machines have also developed rapidly. Some die-casting machines have a tilting mechanism for the clamping mechanism. Die-casting process automation and die-casting computer control and die-casting flexible machining units (FMC) have also been gradually developed.
(1) Oxygenated pressure casting is to fill the pressure chamber and cavity with oxygen before filling the cavity with aluminum metal liquid to replace the air and other gases in it. Its characteristics are: eliminating or reducing air holes and improving the quality of castings; simple structure, convenient operation and low investment.
(2) In vacuum pressure casting, the air in the die-casting cavity is evacuated first, and then the liquid metal is pressed. Its characteristics are: it can eliminate or reduce the pores in the die casting, improve the mechanical properties and surface quality of the casting; greatly reduce the back pressure of the cavity during die casting, and can use lower specific pressure and alloy with poor casting performance
Conventional Die Casting VS Vacuum Die Casting Products
Comparison of metallographic structure between ordinary die casting and vacuum die casting (50 times)
Oridinary die casting with vacuum die casting
How vacuum die casting works
Vacuum die casting involves a steel die equipped with a vacuum valve at the top of die that connected vacuum pump device aside, a casting machine. Molten metal enters the die while vacuum pump starts to work and control by vacuum valve, creating a pressure differential between the die cavity and the molten metal in the crucible. This pressure differential causes the molten metal to flow up the sprue and into the die cavity, where it solidifies. The die is opened, and the casting parts is ejected. The cycle is then repeated with each shot producing from one to several castings, depending on the number of cavities in the die.
Key vacuum casting process elements
Factors affecting the following aspects of vacuum die casting. The design and manufacturing of the vacuum die casting mold process is the key to determining the quality of the casting.
1. Due to the very large clamping force of the die casting machine, the mold parting surface is prone to stress and deformation after extrusion. The flatness and tightness of the mold processing have very high requirements.
2. The control of the air leakage phenomena such as the side clearance of the mold row slider, the clearance between the thimble and the melting cup gate sleeve will directly affect the effect of high vacuum pumping
3. Melting technology: control of indicators such as degassing, slag removal and hydrogen content;
4. Setting of process parameters of die-casting equipment, etc.
5. Mould and vacuum component maintenance frequency
6. Vacuum level in die cavity is less than 50 millibar
7. Special die sealing (cavity, plunger tip, all inserts, ejector pins)
8. Vacuum die components for sealing
9. Control system for die temperature.
10. Die lube spray program control
11. Advanced process monitoring and control system.
12. W3 alloy (ductile)
Advantages Of Vacuum Die Casting
1) Mitigate or remove burning marks on the casting part.
2) Improve shrink marks by enhance cavity filling
3) Improved static, mechanic and dynamic properties
4) Vacuum casting can improve heat treatment of die cast part.
5) Vacuum die casting can improve weldability for cast parts.
6) Vacuum die casting can eliminate or reduce porosities inside the die casting,
7) Improve the mechanical properties and surface quality of the die casting,
8) Improve casting part plating performance.
9) The vacuum die-casting method greatly reduces the back pressure of the cavity, It can use a lower specific pressure, and it is possible to die-cast a larger casting with a small machine
10) The vacuum die-casting improves the filling conditions to cast thinner parts.
11) Compared with the ordinary die casting, the vacuum die casting has almost the same production efficiency.
12) Reduced injection pressure and gate speed
13) Extend tool service life
Disadvantages of vacuum die casting
1) The mold sealing structure is complicated than ordinary casting, it is challenging to making and installing, so the cost is high.
2) It is challenging for the process control of vacuum casting, if it out of control, the result will not obvious.
Application scope of vacuum die casting
1. High-strength structural parts
2. Airtight parts
3. Auto parts
4. Communication filter
5. Pure aluminum / alumina parts
6. Plating parts
7. Power tools
8. Other high-quality die-casting parts
FAQ
Q: Does samples available before order?
A: Yes, if it is the stock product, the sample can be sent for free in 3 days, if customized, will be sent within 7 days.
Q: How about the sample policy?
A: We can provide free sample if the raw material is cheap. However, you have to pay the cost of courier by express like: DHL, TNT, UPS and FEDEX.
Q: Can you make my designs?
A: Yes, OEM/ODM is welcome, pls feel free to send us pictures. If necessary, we can keep your design be protected under law.we will sign NDA with you.
Q: Can I place mix order?
A: Yes, you can mix colour and style in our stock items.
Q: Can I get discounts?
A: Yes, for big order, old customer and frequent customers, we give reasonable discounts.
Q: Which Shipment way is available?
A: By sea to your nearest port. By air to your nearest airport. By express (DHL, UPS, FEDEX, TNT, EMS) to your door.
Q: What is the payment method?
A: We accept TT (Bank Transfer), Western Union, L/C, Paypal.
1. For total amount under US$500, 100% in advance.
2. For total amount above US$500, 30% in advance, the rest before shipment.
Q: What is the quality of your product?
A: We specialized in high quality products, we have rich experience in manufacturering.
Q: what is your core competence?
A: we have advance software to simulate and give you constrictive solution for your project, especially, we prefer to challenge part. We鈥檇 like low volume and high mix prats.
Q: Can you make casting according to our drawing?
A: Yes, we can make casting according to your drawing, 2D drawing, or 3D cad model. If the 3D cad model can be supplied, the development of the tooling can be more efficient. But without 3D, based on 2D drawing we can still make the samples properly approved.
Vacuum Application StudyDie Casting factory
website:http://www.yi-hitech.com/die-casting/