Fondarex Vacuum Technology AND APPLICATON .ppt

VACUUM TECHNOLOGY AND APPLICATION IN HPDC

1. DIE CASTING VACUUM SYSTEMS FONDAREX
®
VACUUM TECHNOLOGY FOR VACUUM TECHNOLOGY FOR
HIGH QUALITY DIECASTINGHIGH QUALITY DIECASTING
Presentation for vacuum usersPresentation for vacuum users

2. DIE CASTING VACUUM SYSTEMS FONDAREX
®
Johann EmmeneggerJohann Emmenegger
Technical EngineerTechnical Engineer
FONDAREX SAFONDAREX SA
CH-1806 ST-LEGIERCH-1806 ST-LEGIER
SWITZERLANDSWITZERLAND

3. DIE CASTING VACUUM SYSTEMS FONDAREX
®
Established in 1946 Established in 1946

4. DIE CASTING VACUUM SYSTEMS FONDAREX
®
We are:We are:
and:and:
certificatedcertificated

5. DIE CASTING VACUUM SYSTEMS FONDAREX
®
HISTORYHISTORY
• 1946 company was founded as a diecasting shop1946 company was founded as a diecasting shop
• 1952 development of first vacuum system 1952 development of first vacuum system 
• 1978 stop of diecasting production1978 stop of diecasting production
• - concentration on vacuum technologie - concentration on vacuum technologie
• 1994 new products presented at the GIFA exhibition1994 new products presented at the GIFA exhibition
• 1997 ISO 9001 Certification1997 ISO 9001 Certification
• 2000 New facilities for higher capacity2000 New facilities for higher capacity

6. DIE CASTING VACUUM SYSTEMS FONDAREX
®
Worldwide presence and serviceWorldwide presence and service
• Headquarters in St. Légier SwitzerlandHeadquarters in St. Légier Switzerland
• North America branchNorth America branch
• Asian branch in Hong KongAsian branch in Hong Kong
• More than 25 agents worldwideMore than 25 agents worldwide
• World leader in vacuum diecasting technologyWorld leader in vacuum diecasting technology

7. DIE CASTING VACUUM SYSTEMS FONDAREX
®
CONTENTS: CONTENTS:
•Vacuum definition in diecastingVacuum definition in diecasting
• Need for vacuum in several industriesNeed for vacuum in several industries
• Different vacuum systems available Different vacuum systems available
worldwide worldwide
• University research on vacuumUniversity research on vacuum
• Requirements for an application studyRequirements for an application study
• Case studiesCase studies
• Trial run conditions Trial run conditions
• Q & AQ & A
General information about DC vacuum technology & applicationsGeneral information about DC vacuum technology & applications

8. DIE CASTING VACUUM SYSTEMS FONDAREX
®
ADVANTAGES OF VACUUMADVANTAGES OF VACUUM
• Higher Quality on die casted partsHigher Quality on die casted parts
• Possibility to cast more difficult parts Possibility to cast more difficult parts
• Reduction of injection pressureReduction of injection pressure
• Reduction of scraps ratesReduction of scraps rates
• Increases die & HPDC machines lifeIncreases die & HPDC machines life
• Pay back within 6 to 12 monthsPay back within 6 to 12 months

9. DIE CASTING VACUUM SYSTEMS FONDAREX
®
Vacuum...Vacuum...
The word vacuum The word vacuum stemsstems from the Latin word from the Latin word
“
 
“
 
vacuusvacuus 
”,
 
”,
which means which means “
 
“
 
emptyempty 
”
 
”
. It . It
therefore describes the condition of an enclosed therefore describes the condition of an enclosed
space which is empty of gas with respect to the space which is empty of gas with respect to the
atmosphere.atmosphere.
The word vacuum The word vacuum stemsstems from the Latin word from the Latin word
“
 
“
 
vacuusvacuus 
”,
 
”,
which means which means “
 
“
 
emptyempty 
”
 
”
. It . It
therefore describes the condition of an enclosed therefore describes the condition of an enclosed
space which is empty of gas with respect to the space which is empty of gas with respect to the
atmosphere.atmosphere.

10. DIE CASTING VACUUM SYSTEMS FONDAREX
®
Vacuum measurements are
 :
Vacuum measurements are
 :
bar (kg/cmbar (kg/cm
22
))= 1000 mbar ( 1019 g/cm= 1000 mbar ( 1019 g/cm
22
))
= 100'000 Pa (Pascal) = N/m= 100'000 Pa (Pascal) = N/m
22
= 750 Torr (mm/Mercury) = 750 Torr (mm/Mercury)
= 29,53 Inch/Mercury (inch/Hg) = 29,53 Inch/Mercury (inch/Hg)
= 14,5 psi (lb/square inch)= 14,5 psi (lb/square inch)
  
1 inch/Hg1 inch/Hg = 25,4 Torr= 25,4 Torr
= 0,491 psi= 0,491 psi
= 0,0339 bar = 0,0339 bar
= 33,86 mbar= 33,86 mbar
= 3386,4 Pa= 3386,4 Pa
bar (kg/cmbar (kg/cm
22
))= 1000 mbar ( 1019 g/cm= 1000 mbar ( 1019 g/cm
22
))
= 100'000 Pa (Pascal) = N/m= 100'000 Pa (Pascal) = N/m
22
= 750 Torr (mm/Mercury) = 750 Torr (mm/Mercury)
= 29,53 Inch/Mercury (inch/Hg) = 29,53 Inch/Mercury (inch/Hg)
= 14,5 psi (lb/square inch)= 14,5 psi (lb/square inch)
  
1 inch/Hg1 inch/Hg = 25,4 Torr= 25,4 Torr
= 0,491 psi= 0,491 psi
= 0,0339 bar = 0,0339 bar
= 33,86 mbar= 33,86 mbar
= 3386,4 Pa= 3386,4 Pa

11. DIE CASTING VACUUM SYSTEMS FONDAREX
®
Air Pressure DiagramAir Pressure Diagram

12. DIE CASTING VACUUM SYSTEMS FONDAREX
®
VACUUM VALUES & APPLICATIONSVACUUM VALUES & APPLICATIONS
Note: In vacuum die casting, anything less than 50 mbar is considered Note: In vacuum die casting, anything less than 50 mbar is considered
«
 high vacuum »
«
 high vacuum »
Rough Vacuum:Rough Vacuum:1000 to 1 mbar1000 to 1 mbar Packaging/DC Packaging/DC
Fine Vacuum:Fine Vacuum:1 to 0,0001 mbar Light bulbs1 to 0,0001 mbar Light bulbs
High Vacuum:High Vacuum:0,0001 to 100,0001 to 10
-7-7
Metallurgy Metallurgy
Super High V.:Super High V.:1010
-7-7
and better and better Space simulation Space simulation
Rough Vacuum:Rough Vacuum:1000 to 1 mbar1000 to 1 mbar Packaging/DC Packaging/DC
Fine Vacuum:Fine Vacuum:1 to 0,0001 mbar Light bulbs1 to 0,0001 mbar Light bulbs
High Vacuum:High Vacuum:0,0001 to 100,0001 to 10
-7-7
Metallurgy Metallurgy
Super High V.:Super High V.:1010
-7-7
and better and better Space simulation Space simulation
Note: In vacuum die casting, anything less than 50 mbar is considered Note: In vacuum die casting, anything less than 50 mbar is considered
«
 high vacuum »
«
 high vacuum »

13. DIE CASTING VACUUM SYSTEMS FONDAREX
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The pressure die casting vacuum systemThe pressure die casting vacuum system

14. DIE CASTING VACUUM SYSTEMS FONDAREX
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Influencing the air movement inside the die cavityInfluencing the air movement inside the die cavity

15. DIE CASTING VACUUM SYSTEMS FONDAREX
®
The pressure The pressure
inside the die inside the die
cavitycavity
Venting of dies : Air pressure diagram
Psi mbar
3100
42,73000
2900
2800
2700
2600
35,62500
2400
2300
2200
2100
28,42000
1900
1800
1700
1600
21,31500
1400
1300
1200 Vacuum
1100
14,21000 0
900 - 100
800 - 200
700 - 300
600 - 400
7,1 500 - 500
400 - 600
300 - 700
200 - 800
100 - 900
0 0 - 1000

16. DIE CASTING VACUUM SYSTEMS FONDAREX
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The vacuum level inside the die cavity mainly depends on:The vacuum level inside the die cavity mainly depends on:
- the tool tightness (closing) - the tool tightness (closing)
- and how clean (dry) it is- and how clean (dry) it is
Other influences to create vacuum in the die cavity:Other influences to create vacuum in the die cavity:
- piston speed used in the casting process- piston speed used in the casting process
- plunger tightness in the shoot sleeve- plunger tightness in the shoot sleeve
- ratio of tank and tool volumes- ratio of tank and tool volumes
- vacuum channel lengths and cross-sections (resistance)- vacuum channel lengths and cross-sections (resistance)
- vacuum valve size (capacity)- vacuum valve size (capacity)
- attachment of the casting part by vacuum gates/channel- attachment of the casting part by vacuum gates/channel
- construction of the mold- construction of the mold
- processing ( machining, polishing )- processing ( machining, polishing )
- the tool tightness (closing) - the tool tightness (closing)
- and how clean (dry) it is- and how clean (dry) it is
Other influences to create vacuum in the die cavity:Other influences to create vacuum in the die cavity:
- piston speed used in the casting process- piston speed used in the casting process
- plunger tightness in the shoot sleeve- plunger tightness in the shoot sleeve
- ratio of tank and tool volumes- ratio of tank and tool volumes
- vacuum channel lengths and cross-sections (resistance)- vacuum channel lengths and cross-sections (resistance)
- vacuum valve size (capacity)- vacuum valve size (capacity)
- attachment of the casting part by vacuum gates/channel- attachment of the casting part by vacuum gates/channel
- construction of the mold- construction of the mold
- processing ( machining, polishing )- processing ( machining, polishing )

17. DIE CASTING VACUUM SYSTEMS FONDAREX
®
Factors in the die casting process to reach top qualityFactors in the die casting process to reach top quality
Of course there are many factors to reach top quality die casting ;Of course there are many factors to reach top quality die casting ;

- die design/ lay out/ precision - die design/ lay out/ precision
- gating and runner system - gating and runner system
- venting (vacuum)- venting (vacuum)
- die temperature - die temperature
- die casting machine performance - die casting machine performance
- die casting machine setting- die casting machine setting
- plunger and shot sleeve precision - plunger and shot sleeve precision
- casting alloy quality - casting alloy quality
- lubricants (quality and use) - lubricants (quality and use)
Of course there are many factors to reach top quality die casting ;Of course there are many factors to reach top quality die casting ;

- die design/ lay out/ precision - die design/ lay out/ precision
- gating and runner system - gating and runner system
- venting (vacuum)- venting (vacuum)
- die temperature - die temperature
- die casting machine performance - die casting machine performance
- die casting machine setting- die casting machine setting
- plunger and shot sleeve precision - plunger and shot sleeve precision
- casting alloy quality - casting alloy quality
- lubricants (quality and use) - lubricants (quality and use)

18. DIE CASTING VACUUM SYSTEMS FONDAREX
®
Industries requiring vacuumIndustries requiring vacuum
• Automotive partsAutomotive parts
• Household devicesHousehold devices
• Hydraulic componentsHydraulic components
• Computer componentsComputer components
• Heating systemsHeating systems
• Safety part for the gas industrySafety part for the gas industry
• Automotive partsAutomotive parts
• Household devicesHousehold devices
• Hydraulic componentsHydraulic components
• Computer componentsComputer components
• Heating systemsHeating systems
• Safety part for the gas industrySafety part for the gas industry

19. DIE CASTING VACUUM SYSTEMS FONDAREX
®
Which secondary process will profit by the use Which secondary process will profit by the use
of vacuum technology?of vacuum technology?
Die casting parts who have to be:Die casting parts who have to be:
-machined, machined,
-weldedwelded
- thermally or chemically processed, - thermally or chemically processed,
- plated,- plated,
- Teflon coated, - Teflon coated,
- powder coated, - powder coated,
- painted, - painted,
- hardened, without surface damage.- hardened, without surface damage.
Die casting parts who have to be:Die casting parts who have to be:
-machined, machined,
-weldedwelded
- thermally or chemically processed, - thermally or chemically processed,
- plated,- plated,
- Teflon coated, - Teflon coated,
- powder coated, - powder coated,
- painted, - painted,
- hardened, without surface damage.- hardened, without surface damage.

20. DIE CASTING VACUUM SYSTEMS FONDAREX
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DIFFERENT VACUUM SYSTEMSDIFFERENT VACUUM SYSTEMS
• Chill BlockChill Block
• Path/Time dependantPath/Time dependant
• Metal Flow actuatedMetal Flow actuated
• Chill BlockChill Block
• Path/Time dependantPath/Time dependant
• Metal Flow actuatedMetal Flow actuated

21. DIE CASTING VACUUM SYSTEMS FONDAREX
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Chill BlockChill Block
•Start signal is given by Start signal is given by
plungerplunger
•Vacuum is stopped by metal Vacuum is stopped by metal
freezing in the chill blockfreezing in the chill block
•No control possibilitiesNo control possibilities
•If metal does not freeze it If metal does not freeze it
will be sucked into vacuum will be sucked into vacuum
unitunit
•Limited evacuation capacityLimited evacuation capacity
Start Vacuum

22. DIE CASTING VACUUM SYSTEMS FONDAREX
®
Path / Time dependentPath / Time dependent
•Start signal is given by the Start signal is given by the
movement of the plungermovement of the plunger
•Stop signal is given by Stop signal is given by
switch on the plunger or switch on the plunger or
by delay timerby delay timer
•Vacuum stops before end Vacuum stops before end
of casting process of casting process
•Limited parameter Limited parameter
possibilitiespossibilities
Start Vacuum
Stop Vacuum

23. DIE CASTING VACUUM SYSTEMS FONDAREX
®
Metal Flow ActuatedMetal Flow Actuated
•Vacuum start signal by Vacuum start signal by
plunger movement plunger movement
•Delay possibilitiesDelay possibilities
•Valve stays open until the Valve stays open until the
end of the casting processend of the casting process
•Valves is triggered by the Valves is triggered by the
molten metalmolten metal
•Measurement of vacuum Measurement of vacuum
level inside the cavitylevel inside the cavity
Start Vacuum

24. DIE CASTING VACUUM SYSTEMS FONDAREX
®
UNIVERSITY RESEARCHUNIVERSITY RESEARCH
•Ohio State University, Colombus (USA)Ohio State University, Colombus (USA)
•Technical university, Braunschweig (Germany)Technical university, Braunschweig (Germany)
•Product research Center of Cominco (Canada)Product research Center of Cominco (Canada)

25. DIE CASTING VACUUM SYSTEMS FONDAREX
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Scrap ReductionScrap Reduction
Ohio state UniversityOhio state University

26. DIE CASTING VACUUM SYSTEMS FONDAREX
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Gas content in CastingsGas content in Castings
Ohio state UniversityOhio state University
Casting with a Casting with a
metal flow metal flow
actuated vacuum actuated vacuum
system reduces system reduces
the gas content in the gas content in
the die cast part the die cast part
by 54% up to by 54% up to
90% depending 90% depending
on machine on machine
andpereferic andpereferic
parameters.parameters.

27. DIE CASTING VACUUM SYSTEMS FONDAREX
®
Metallographic AnalysisMetallographic Analysis

With vacuum (50X)With vacuum (50X)

Without vacuum (50x)Without vacuum (50x)
Ohio state UniversityOhio state University

28. DIE CASTING VACUUM SYSTEMS FONDAREX
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Study on weldabilityStudy on weldability

Without vacuumWithout vacuum

With vacuumWith vacuum
Braunschweig UniversityBraunschweig University
Vacuum system in diecasting has a considerable influence on Vacuum system in diecasting has a considerable influence on
the weldability of die casted partsthe weldability of die casted parts

29. DIE CASTING VACUUM SYSTEMS FONDAREX
®
Cominco Research center : Cominco Research center :
Study on different venting systemsStudy on different venting systems
Overflow ventingOverflow ventingFirst Phase First Phase
vacuum ventingvacuum venting
Vacuum venting Vacuum venting
during whole during whole
casting processcasting process
By far best results with a complete vacuum system.By far best results with a complete vacuum system.

30. DIE CASTING VACUUM SYSTEMS FONDAREX
®
Connections required for a Fondarex Connections required for a Fondarex
vacuum unitvacuum unit
• 380 V triple phase, 3 A 380 V triple phase, 3 A
• or 220 V single phase, 3 A (Minivac only)or 220 V single phase, 3 A (Minivac only)
• Compressed air 5 bar minCompressed air 5 bar min
• Signal " vacuum start " (plunger forward)Signal " vacuum start " (plunger forward)
• Signal " die open "Signal " die open "
• 380 V triple phase, 3 A 380 V triple phase, 3 A
• or 220 V single phase, 3 A (Minivac only)or 220 V single phase, 3 A (Minivac only)
• Compressed air 5 bar minCompressed air 5 bar min
• Signal " vacuum start " (plunger forward)Signal " vacuum start " (plunger forward)
• Signal " die open "Signal " die open "

31. DIE CASTING VACUUM SYSTEMS FONDAREX
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32. DIE CASTING VACUUM SYSTEMS FONDAREX
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New products and services on a yearly basisNew products and services on a yearly basis
Supervac pulse Supervac pulse
valves with valves with
sleeves; on sleeves; on
overhaule units; overhaule units;
July 2002 - July 2002 -
on new valves; on new valves;
End of 2002End of 2002
VACUUPAC MINI VACUUPAC MINI
July 2002 July 2002

33. DIE CASTING VACUUM SYSTEMS FONDAREX
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34. DIE CASTING VACUUM SYSTEMS FONDAREX
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Information for a vacuum applicationInformation for a vacuum application
1.1. Part (drawing or casting)Part (drawing or casting)
2.2. Die drawing (electronic format if possible .dxf, .dwg)Die drawing (electronic format if possible .dxf, .dwg)
3.3. Part weight, weight after gate, shot weight Part weight, weight after gate, shot weight
4.4. Technical information, such as shot sleeve length, max. Piston Technical information, such as shot sleeve length, max. Piston
diameter, Die casting machine size, Hot oil units, diameter, Die casting machine size, Hot oil units,
Lubrifications system etc.Lubrifications system etc.
5.5. Details on existing problemsDetails on existing problems
6. 6. Fondarex application sheet or technical data sheetFondarex application sheet or technical data sheet
   The more information are available, the easier it is to work out an optimal The more information are available, the easier it is to work out an optimal
vacuum application!vacuum application!

35. DIE CASTING VACUUM SYSTEMS FONDAREX
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The Construction of a vacuum channelThe Construction of a vacuum channel

36. DIE CASTING VACUUM SYSTEMS FONDAREX
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The air flow in the channelThe air flow in the channel

37. DIE CASTING VACUUM SYSTEMS FONDAREX
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The metal flow in the channelThe metal flow in the channel

38. DIE CASTING VACUUM SYSTEMS FONDAREX
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Detail of FONDAREX SUPERVAC VACUUM VALVEDetail of FONDAREX SUPERVAC VACUUM VALVE

39. DIE CASTING VACUUM SYSTEMS FONDAREX
®
The Supervac vacuum valves seriesThe Supervac vacuum valves series
200 – 800 T200 – 800 T0.6 – 4 kg0.6 – 4 kgMEDIO/MEDIO-PMEDIO/MEDIO-P
600 – 2000 T600 – 2000 T3 – 9 kg3 – 9 kgMAXIMAXI
To 400 TTo 400 T0.1 – 0.9 kg0.1 – 0.9 kgMINI/MINI-PMINI/MINI-P
1600 – 4000 T1600 – 4000 T8 – 18 kg8 – 18 kgMACROMACRO
To 250 TTo 250 T0.05 – 0.3 kg0.05 – 0.3 kgMICRO-PMICRO-P
DCM closing forceDCM closing forceParts WeightParts WeightValve TypeValve Type

40. DIE CASTING VACUUM SYSTEMS FONDAREX
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Factors which may decide the choice of valve:Factors which may decide the choice of valve:
• evacuation volumeevacuation volume
• the maximum vacuum channel and vacuum gate the maximum vacuum channel and vacuum gate
size for evacuationsize for evacuation
• Die casting machine sizeDie casting machine size
• the other moulds in the rangethe other moulds in the range
• the space available on the mould/mould depth to the space available on the mould/mould depth to
set the vacuum valve set the vacuum valve
• casting material Al, Zn, Mg or Pbcasting material Al, Zn, Mg or Pb
• evacuation volumeevacuation volume
• the maximum vacuum channel and vacuum gate the maximum vacuum channel and vacuum gate
size for evacuationsize for evacuation
• Die casting machine sizeDie casting machine size
• the other moulds in the rangethe other moulds in the range
• the space available on the mould/mould depth to the space available on the mould/mould depth to
set the vacuum valve set the vacuum valve
• casting material Al, Zn, Mg or Pbcasting material Al, Zn, Mg or Pb

41. DIE CASTING VACUUM SYSTEMS FONDAREX
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Example of vacuum requirement calculation:Example of vacuum requirement calculation:
Part weight after gate (Al):Part weight after gate (Al): 12 kg12 kg
DCM tonnage:DCM tonnage: 2700 t2700 t
Piston diam.:Piston diam.: 130 mm130 mm
Maxi P valve evacuation capacity:Maxi P valve evacuation capacity: 9,0 l/s (2x)9,0 l/s (2x)
Evacuation section:Evacuation section: 120 mm120 mm
22
(2x) (2x)
Shot volume:Shot volume: 11 l + 4l* = 15 l11 l + 4l* = 15 l
Vacupac 4.1 tank capacity:Vacupac 4.1 tank capacity: 300 l300 l
Maximum vacuum level inside the tank:Maximum vacuum level inside the tank: < 5 mbar< 5 mbar
Estimated evacuation time:Estimated evacuation time: 0,8 sec0,8 sec
Tank volume available after 1 shot:Tank volume available after 1 shot: 94.5 %94.5 %
*Air volume contained inside the evacuation hoses (5m)*Air volume contained inside the evacuation hoses (5m)
Part weight after gate (Al):Part weight after gate (Al): 12 kg12 kg
DCM tonnage:DCM tonnage: 2700 t2700 t
Piston diam.:Piston diam.: 130 mm130 mm
Maxi P valve evacuation capacity:Maxi P valve evacuation capacity: 9,0 l/s (2x)9,0 l/s (2x)
Evacuation section:Evacuation section: 120 mm120 mm
22
(2x) (2x)
Shot volume:Shot volume: 11 l + 4l* = 15 l11 l + 4l* = 15 l
Vacupac 4.1 tank capacity:Vacupac 4.1 tank capacity: 300 l300 l
Maximum vacuum level inside the tank:Maximum vacuum level inside the tank: < 5 mbar< 5 mbar
Estimated evacuation time:Estimated evacuation time: 0,8 sec0,8 sec
Tank volume available after 1 shot:Tank volume available after 1 shot: 94.5 %94.5 %
*Air volume contained inside the evacuation hoses (5m)*Air volume contained inside the evacuation hoses (5m)

42. DIE CASTING VACUUM SYSTEMS FONDAREX
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FONDAREX PHILOSOPHYFONDAREX PHILOSOPHY
• Propose a suitable vacuum solution for each applicationPropose a suitable vacuum solution for each application
• Provide technical suggestions for die modifications & die casting Provide technical suggestions for die modifications & die casting
operationoperation
• Emphasize on building a precise die Emphasize on building a precise die
• Provide technical assistance during production start upProvide technical assistance during production start up
• Provide fast & efficient after sales service as well as regular Provide fast & efficient after sales service as well as regular
training and on going educationtraining and on going education
• Establish a long term relationship with each customerEstablish a long term relationship with each customer
• Improve continiously the products & servicesImprove continiously the products & services
• Propose a suitable vacuum solution for each applicationPropose a suitable vacuum solution for each application
• Provide technical suggestions for die modifications & die casting Provide technical suggestions for die modifications & die casting
operationoperation
• Emphasize on building a precise die Emphasize on building a precise die
• Provide technical assistance during production start upProvide technical assistance during production start up
• Provide fast & efficient after sales service as well as regular Provide fast & efficient after sales service as well as regular
training and on going educationtraining and on going education
• Establish a long term relationship with each customerEstablish a long term relationship with each customer
• Improve continiously the products & servicesImprove continiously the products & services

43. DIE CASTING VACUUM SYSTEMS FONDAREX
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Adapting a vacuum valve to the mould Adapting a vacuum valve to the mould
Possibilities to incorporatePossibilities to incorporate
the vacuum valve on or the vacuum valve on or
into the die holderinto the die holder

44. DIE CASTING VACUUM SYSTEMS FONDAREX
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Fastening the valve on the moldFastening the valve on the mold

45. DIE CASTING VACUUM SYSTEMS FONDAREX
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Fitting the valve into the die holderFitting the valve into the die holder

46. DIE CASTING VACUUM SYSTEMS FONDAREX
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Attention on precision, parallelism and die bendingAttention on precision, parallelism and die bending

47. DIE CASTING VACUUM SYSTEMS FONDAREX
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Example of channel design for SUPERVAC MEDIO-PExample of channel design for SUPERVAC MEDIO-P

48. DIE CASTING VACUUM SYSTEMS FONDAREX
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Examples of
different
vacuum
applications:

49. DIE CASTING VACUUM SYSTEMS FONDAREX
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50. DIE CASTING VACUUM SYSTEMS FONDAREX
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51. DIE CASTING VACUUM SYSTEMS FONDAREX
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52. DIE CASTING VACUUM SYSTEMS FONDAREX
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Example of Example of
vacuum channel vacuum channel
connection with connection with
existing overflowsexisting overflows

53. DIE CASTING VACUUM SYSTEMS FONDAREX
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Example of a hot Example of a hot
chamber vacuum chamber vacuum
applicationapplication
2 cavity handle 2 cavity handle
vacuum die with vacuum die with
one Supervac Mini one Supervac Mini
P Vacuum ValveP Vacuum Valve
integrated into the integrated into the
mould framemould frame

54. DIE CASTING VACUUM SYSTEMS FONDAREX
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Practical Practical
example:example:
Two cavity Two cavity
gearbox housing gearbox housing
with one with one
Supervac Macro Supervac Macro
vacuum valvevacuum valve
Vacuum channelVacuum channel
Vacuum valve / Vacuum valve /
CompensatorCompensator
Vacuum gatesVacuum gates

55. DIE CASTING VACUUM SYSTEMS FONDAREX
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Two cavity oilsump with two Two cavity oilsump with two
Supervac Maxi-P vacuum valves. Supervac Maxi-P vacuum valves.
This is a high ductile part which This is a high ductile part which
is heat treatedis heat treated

56. DIE CASTING VACUUM SYSTEMS FONDAREX
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Engine BlockEngine Block
•Weight: Weight: 11, 2 kg11, 2 kg
•Valve type:Valve type: MacroMacro
•Alloy:Alloy: alu 231alu 231
•1 Cavity1 Cavity
•Character:Character:complex part, cast with complex part, cast with
• 4 slide cores4 slide cores
some rips are critical to fillsome rips are critical to fill
low fill time requiredlow fill time required
•Expected Achievements:Expected Achievements:
porosity free, tight.porosity free, tight.
and completely filledand completely filled
after machining works is after machining works is
important!important!
•Weight: Weight: 11, 2 kg11, 2 kg
•Valve type:Valve type: MacroMacro
•Alloy:Alloy: alu 231alu 231
•1 Cavity1 Cavity
•Character:Character:complex part, cast with complex part, cast with
• 4 slide cores4 slide cores
some rips are critical to fillsome rips are critical to fill
low fill time requiredlow fill time required
•Expected Achievements:Expected Achievements:
porosity free, tight.porosity free, tight.
and completely filledand completely filled
after machining works is after machining works is
important!important!

57. DIE CASTING VACUUM SYSTEMS FONDAREX
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Gear Box CoverGear Box Cover
- Weight: - Weight: 3,9 kg3,9 kg
• Valve type: Valve type: MaxiMaxi
• Alloy:Alloy: MgMg
• Cavity: Cavity: 11
• Character:Character:deep implant, deep implant,
difficult difficult to weldto weld
low fill timelow fill time
• Expected Achievements:Expected Achievements:
porosity free, after porosity free, after
machiningmachining
without defectswithout defects
- Weight: - Weight: 3,9 kg3,9 kg
• Valve type: Valve type: MaxiMaxi
• Alloy:Alloy: MgMg
• Cavity: Cavity: 11
• Character:Character:deep implant, deep implant,
difficult difficult to weldto weld
low fill timelow fill time
• Expected Achievements:Expected Achievements:
porosity free, after porosity free, after
machiningmachining
without defectswithout defects

58. DIE CASTING VACUUM SYSTEMS FONDAREX
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Steering bodySteering body

59. DIE CASTING VACUUM SYSTEMS FONDAREX
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Steering wheelSteering wheel
•Casting:Casting: Steering Wheel Steering Wheel
Weight: Weight: 0,304 kg0,304 kg
•Valve type: Valve type: Medio-PMedio-P
•Alloy:Alloy:MgMg
•Cavity: Cavity: 11
•Character:Character: low fill time,low fill time,
long filling waylong filling way
•Expected Achievements:Expected Achievements:
porosity free, porosity free,
elongation poor,elongation poor,
bending possiblebending possible

60. DIE CASTING VACUUM SYSTEMS FONDAREX
®
Motorcycle Gearbox coverMotorcycle Gearbox cover
•Weight: 1,62 kg
•Valve type: Medio-P
•Alloy: Alu 226
•Cavity: 1
•Character: thin walled
•Expected Achievements:
porosity free,
no leak

61. DIE CASTING VACUUM SYSTEMS FONDAREX
®
Sanitary tapsSanitary taps
•Weight: Weight: 2x0,280 2x0,280
•Valve type: Valve type: MiniMini
•Alloy:Alloy:Zinc Zinc
•Cavities:Cavities: 22
•Expected Achievements:Expected Achievements:
nice surface, nice surface, chrome chrome
platingplating

62. DIE CASTING VACUUM SYSTEMS FONDAREX
®
Burago miniature carsBurago miniature cars

63. DIE CASTING VACUUM SYSTEMS FONDAREX
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64. DIE CASTING VACUUM SYSTEMS FONDAREX
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TRIAL RUNTRIAL RUN
• Application study (evacuation channels)Application study (evacuation channels)
• On site trial during 2-3 daysOn site trial during 2-3 days
• Assistance by skilled technical staffAssistance by skilled technical staff
• Training on vacuum diecastingTraining on vacuum diecasting
• Application study (evacuation channels)Application study (evacuation channels)
• On site trial during 2-3 daysOn site trial during 2-3 days
• Assistance by skilled technical staffAssistance by skilled technical staff
• Training on vacuum diecastingTraining on vacuum diecasting

65. DIE CASTING VACUUM SYSTEMS FONDAREX
®
TRIAL ADVANTAGESTRIAL ADVANTAGES
• You can quantify your benefits You can quantify your benefits
• Easier investment Vs purchasingEasier investment Vs purchasing
• Get confident with this technologyGet confident with this technology
• Allows Pay back calculation Allows Pay back calculation
• You can quantify your benefits You can quantify your benefits
• Easier investment Vs purchasingEasier investment Vs purchasing
• Get confident with this technologyGet confident with this technology
• Allows Pay back calculation Allows Pay back calculation

66. DIE CASTING VACUUM SYSTEMS FONDAREX
®
CONCLUSIONCONCLUSION
• Not all diecasting parts need vacuumNot all diecasting parts need vacuum
• Vacuum = quality = added valueVacuum = quality = added value
• Evolution and not RevolutionEvolution and not Revolution
• Vacuum belongs to state of the art diecastingVacuum belongs to state of the art diecasting
• Only trust a partner with experience & required Only trust a partner with experience & required
business size.business size.
• Not all diecasting parts need vacuumNot all diecasting parts need vacuum
• Vacuum = quality = added valueVacuum = quality = added value
• Evolution and not RevolutionEvolution and not Revolution
• Vacuum belongs to state of the art diecastingVacuum belongs to state of the art diecasting
• Only trust a partner with experience & required Only trust a partner with experience & required
business size.business size.

67. DIE CASTING VACUUM SYSTEMS FONDAREX
®