Innovations in Vacuum Die Casting:

Vacuum Technology for High Quality Die Casting Parts

Johann Emmenegger, Engineering Director & Instructor

ADCA-AFI Joint Casting Conference – October 9-11, 2016

Deakin Waterfront Campus, Geelong, Victoria, Australia
Fondarex world
Consulting
Vacuum project recommendation
Vacuum application study
Vacuum system
Vacuum valve
Chill-block
Technical support
Spare parts
Training
Forum

ADCA-AFI Joint Casting Conference – October 9-11, 2016

Deakin Waterfront Campus, Geelong, Victoria, Australia COPYRIGHT © 2016 FONDAREX SA 4
The pressure die casting vacuum system:

ADCA-AFI Joint Casting Conference – October 9-11, 2016

Deakin Waterfront Campus, Geelong, Victoria, Australia COPYRIGHT © 2016 FONDAREX SA 5
Movement of air and metal inside the shot sleeve
and the runner

ADCA-AFI Joint Casting Conference – October 9-11, 2016

Deakin Waterfront Campus, Geelong, Victoria, Australia COPYRIGHT © 2016 FONDAREX SA 6
Products

SUPERVAC
MONOVAC
MONOVAC MINI MEDIO MAXI MACRO

CHILL-BLOCK
SCCZ 12 SCS 30 SCS 60 SCS 100 SCS 140

ADCA-AFI Joint Casting Conference – October 9-11, 2016

Deakin Waterfront Campus, Geelong, Victoria, Australia COPYRIGHT © 2016 FONDAREX SA 8
ADCA-AFI Joint Casting Conference – October 9-11, 2016
Deakin Waterfront Campus, Geelong, Victoria, Australia COPYRIGHT © 2016 FONDAREX SA 9
Vacuum application studies

Determine the evacuation system

Size and adapt the gating system
Size and adapt vacuum channels

Fondarex advices on production

parameters.

ADCA-AFI Joint Casting Conference – October 9-11, 2016

Deakin Waterfront Campus, Geelong, Victoria, Australia COPYRIGHT © 2016 FONDAREX SA 10
Vacuum application studies
Influence:
Evacuation capacity
> Metal at the gate
Maintenance frequency
> Downtimes
Size of overflows / vacuum channels
> Reduce the amount of metal recycling
Projected area
> Locking force of the die casting machine

ADCA-AFI Joint Casting Conference – October 9-11, 2016

Deakin Waterfront Campus, Geelong, Victoria, Australia COPYRIGHT © 2016 FONDAREX SA 11
To start the vacuum channel lay out:

Fondarex is recommending rather small overflow volume for the following reasons:
− Less alloy passing the die cavity, less die wear - more parts per die, die temperature
control !
− Less alloy recycling
− The «switch over» point from velocity to pressure
is easier to find
− The dynamics of the DCM work better
− Therefore better micro structure of the die cast part
− The projected area can be kept lower
− Therefore less flash
− Less flash means better vacuum, better productivity, better results, geometricaly prezise
parts!
− If a modification is necessary, it is much easier to open a small overflow than to weld a
large one

ADCA-AFI Joint Casting Conference – October 9-11, 2016

Deakin Waterfront Campus, Geelong, Victoria, Australia COPYRIGHT © 2016 FONDAREX SA 12
The vacuum channel basics:

ADCA-AFI Joint Casting Conference – October 9-11, 2016

Deakin Waterfront Campus, Geelong, Victoria, Australia COPYRIGHT © 2016 FONDAREX SA 13
The vacuum channel basics:

ADCA-AFI Joint Casting Conference – October 9-11, 2016

Deakin Waterfront Campus, Geelong, Victoria, Australia COPYRIGHT © 2016 FONDAREX SA 14
The vacuum channel basics:

ADCA-AFI Joint Casting Conference – October 9-11, 2016

Deakin Waterfront Campus, Geelong, Victoria, Australia COPYRIGHT © 2016 FONDAREX SA 15
The vacuum channel basics:

- Use your DC knowledge

(think of extraction!)
- Use new machining
technologies
- Use both die sides
- Do not use too much of
parting line area Force during and after solidification
- Machine nice surfaces
- Use radiuses
- Use mobile and fixed die
side

ADCA-AFI Joint Casting Conference – October 9-11, 2016

Deakin Waterfront Campus, Geelong, Victoria, Australia COPYRIGHT © 2016 FONDAREX SA 16
The vacuum channel basics:

ADCA-AFI Joint Casting Conference – October 9-11, 2016

Deakin Waterfront Campus, Geelong, Victoria, Australia COPYRIGHT © 2016 FONDAREX SA 17
The vacuum channel basics:

ADCA-AFI Joint Casting Conference – October 9-11, 2016

Deakin Waterfront Campus, Geelong, Victoria, Australia COPYRIGHT © 2016 FONDAREX SA 18
Example of a vacuum channel lay out:

ADCA-AFI Joint Casting Conference – October 9-11, 2016

Deakin Waterfront Campus, Geelong, Victoria, Australia COPYRIGHT © 2016 FONDAREX SA 19
Example of a vacuum channel lay out:

ADCA-AFI Joint Casting Conference – October 9-11, 2016

Deakin Waterfront Campus, Geelong, Victoria, Australia COPYRIGHT © 2016 FONDAREX SA 20
Example of a vacuum channel lay out:

ADCA-AFI Joint Casting Conference – October 9-11, 2016

Deakin Waterfront Campus, Geelong, Victoria, Australia COPYRIGHT © 2016 FONDAREX SA 21
Example of a vacuum channel lay out:

ADCA-AFI Joint Casting Conference – October 9-11, 2016

Deakin Waterfront Campus, Geelong, Victoria, Australia COPYRIGHT © 2016 FONDAREX SA 22
Example of a vacuum channel lay out:

ADCA-AFI Joint Casting Conference – October 9-11, 2016

Deakin Waterfront Campus, Geelong, Victoria, Australia COPYRIGHT © 2016 FONDAREX SA 23
Example of a vacuum channel lay out:

ADCA-AFI Joint Casting Conference – October 9-11, 2016

Deakin Waterfront Campus, Geelong, Victoria, Australia COPYRIGHT © 2016 FONDAREX SA 24
Example of a vacuum channel lay out:

ADCA-AFI Joint Casting Conference – October 9-11, 2016

Deakin Waterfront Campus, Geelong, Victoria, Australia COPYRIGHT © 2016 FONDAREX SA 25
Examples of vacuum die casting parts:
Johann Emmenegger, Engineering Director & Instructor

ADCA-AFI Joint Casting Conference – October 9-11, 2016

Deakin Waterfront Campus, Geelong, Victoria, Australia