In the die casting process the amount of air included into the shot sleeve and cavities as well as the gas generated by the liquid metal that cannot be entirely evacuated and micro or macro gas porosity that are always trapped within the final casting.
The major issue is not only related to the possible scrap due to internal porosities (entrapped air and other vapors generated during the process) but also to the increased machine pressure needed to oppose the air and gas resistance and produce good parts. The internal porosities may reduce the structural characteristics of the part and that can lead to aesthetical defects after the surface treatments.
The vacuum system FONDVACUUM combined with the patented technology of the valve design allows the foundries to reach an effective gas evacuation from the die and consequently to achieve high quality castings and to reduce the scrap rate.
The knowledge and the practical foundry experience of the FONDVACUUM team of engineers are at the basis of the integrated vacuum system (machine+valves) that can successfully manage the vacuum in the non-ferrous (zinc, aluminum, magnesium, brass) die casting process.
FONDVACUUM supplies customized design, production, installation and setup of all its vacuum integrated systems. Additionally it provides support and consultancy for the entire casting process (die design, injection parameters, shot sleeve / plunger system and spraying / thermo regulation system) in order to increase the casting final quality.
The FONDVACUUM SYSTEMS major benefits:
- Wide range of applicability (machines from 150T to 4000T)
- Highly affordable and performant vacuum pump
- High precision valve lubrication
- Double Inox net to achieve optimal filtration of metallic particles and pollution control for vacuum channels
- Singlevalve controlled cooling system
- Minimized overall dimensions of the vacuum system frame
- Siemens PLC
- Touch screen monitor for monitoring and measurements
- Userdefined tank vacuum value
- Data upload/download to SD Card
- Transfer data via Ethernet card
There are currently two kind of valves (one for aluminum, magnesium and zinc die casting and another for copper alloy casting) each with four different dimensional versions.
Additionally a patented compensator can be applied or integrated. Its purpose is to steadily seal the fixed plate valve with the moving plate valve.
The system is modular and can be tailored to meet the customer’s needs. The valves can be connected – through customizable adapting plates – to a vacuum system of different brands.
The FONDVACUUM valves – if used properly – may be used for more than 20,000 shots without any maintenance. For brass die casting the valves may endure more than 200,000 cycles for copper alloys and more than 500,000 for aluminum alloys.