Can Production Costs Be Reduced by Vacuum Die Casting?
1. Understand the process of vacuum die casting
The vacuum die-casting process is almost similar to any pressure die-casting technique including semi solid die casting, the only change is the creation of a vacuum in the process. Vacuum-assisted die casting can be used for hot chamber and cold chamber die casting.
Common process explanations of vacuum die casting are: first the metal alloy is melted, with the aid of the plunger in the hot chamber machine and the ladle in the cold chamber machine, the molten metal is moved into the injection chamber, then vacuum creation and metal injection are performed under high pressure, and the air will be expelled from the mold cavity, this will allow the molten metal to reach all grooves evenly, then let it solidify and cool, the finished casting can be retrieved after being ejected from the mold. Different from silica sol casting, vacuum die casting greatly reduces surface defects and may not require any major surface finishing processes.
The vacuum investment casting process is now typically done in three ways: metal is injected after the vacuum is created; metal injection is done simultaneously with vacuum creation; metal injection and vacuum creation are driven by sensors. Therefore, the vacuum die-casting process may vary slightly depending on how a particular die-casting machine works.
2. Reduce production costs through vacuum die casting
Vacuum die casting is a more complicated process than usual and involves a few extra steps. Vacuum-assisted systems, on the other hand, are usually more expensive. Therefore, vacuum die casting should be more expensive than the traditional process, right? But that's not quite true. Because vacuum die casting can greatly reduce defective parts in the production process. You can also offer thinner walls, allowing manufacturers to save more material as well. Therefore, production costs are also reduced due to less waste. There is another factor in the quality and strength of the part. There is no denying that die casting is the most cost-effective manufacturing method for mass-produced parts. But die casting is not suitable for ferrous metals.
If you have very high strength requirements, you may need to cast ferrous metals with more expensive fabrication methods. Fortunately, vacuum die casting can make your parts suitable for heat treatment. Vacuum-assisted aluminum die castings can be heat treated to significantly increase their strength. So you still get the economic advantages of aluminum die casting with vacuum die casting.
3. Will vacuum die casting increase weldability?
Yes. Typically, solderability is an element primarily limited to metals. However, not all metals share this characteristic. This means that in some metals; it is easier to weld than in others. Technically, the weldability of metals is based on their mechanical and microstructural properties. Vacuum die casting gives the part a better microstructure and enhances its integrity of the part. Essentially, this improves die-casting weldability without having to use more expensive materials with higher weldability.