Inox Vacuum Die Casting

Looking for an expert that can help you find innovative vacuum die casting solutions? Inox Cast got your back! We make sure to use special aluminum alloys during the process for your satisfaction. The finished parts by vacuum die casting offers high reliability, high performance, and light in weight.

Most of the products processed by Inox vacuum die casting fully comply with ISO 9001, IATF 16949, and RoHS. With these standards, we can achieve defect-free and high authenticity. During the process, we also used raw materials like stainless steel. You can avail of the products at a competitive price. Send us your ideas and let us make them into reality.

Preferring the vacuum die casting method conducted by Inox Cast offers several advantages and features. The method produces final parts that are dimensionally accurate and stable, durable functions, and close tolerances. Thus, this is heat-resistant, stronger, and high-quality. Vacuum-assisted die casting presenting these numerous benefits:

• More complex, larger, and thinner castings are possible
• Product strength and density are maximized
• Outstanding surface quality is guaranteed
• Less casting pressure is essential

For decades Inox Cast has become a leader in supplying vacuum die castings to the international marketplace. We are dedicated to satisfying our highly valued customers.

Inox Cast serves diverse industries, providing them the complex and simple solutions to production challenges. We are also providing design and engineering support for everyone.

Avail our exceptional services and solutions. Contact now.

Vacuum Die Casting: The Complete FAQ Guide

Vacuum die casting refers to high-pressure die casting process, which involves use of a vacuum pump to eliminate trapped air and gas within die cavity.

This guide explains numerous aspects of this die casting process to ensure you attain high-quality defect-free parts.

Why Should You Opt For Vacuum Die Casting?

Vacuum die casting

Essentially, vacuum die casting offers a wide range of benefits, which is why it is quite popular in various industries.

Some of the beneficial reasons why you’d choose this method over other types of casting techniques include the following;

Guarantees Accurate Casting

It stands out due to its high-precision level, which is vital since it ensures the final product meets your design specifications.

This process produces parts that take every attention to detail into consideration, whether it is simple or complex.

Provides Shorter Cycle Time

This method is immensely fast, making it easy to create your parts within shortest time possible.

You can use about a week to make more than 50 functioning parts using vacuum die casting method.

Therefore, it is an ideal option, especially if you are involved in mass production under strict deadlines.

Enhances Quality Of Products And Parts

Since the method guarantees a high-precision level when creating parts, you can be certain it produces high-quality products.

Besides, the process utilizes resin enabling you to settle on ideal to make the final product.

Relatively Cost-effective

In essence, it is more economical to make a wide range of parts using vacuum die casting.

Moreover, you can use different materials to create more products from the mold, enhancing the cost-effectiveness of the process.

Reduces Defects

It significantly reduces a wide range of casting defects, which is imperative in enhancing the overall quality of manufactured products.

Ideal Dimensional Stability

Vacuum die casting allows you to produce parts with thin walls and undercuts, which are vital geometrical parameters.

Enhances Parts Surface Finish And Mechanical Properties

Technically, this process produces parts with an excellent finish, reducing the need for additional surface coating.

Moreover, vacuum die casting minimizes defects and enables even melt distribution.

In essence, it guarantees improved parts integrity enhanced mechanical strength.

What Are The Limitations Of Vacuum Die Casting?

The initial capital investment is relatively high compared to other die casting methods.

In essence, the machines and tools involved in this process can be quite costly to acquire.

Another shortcoming of this process is that it requires high intensive monitoring and, in some instances, several casting system adjustments.

How Does Vacuum Die Casting Process Work?

Ordinarily, you can perform vacuum die casting process in numerous ways.

However, the main difference among the available techniques is based on vacuum formation in the system.

Nevertheless, vacuum creation and melt injection are the main actions taking place in this entire die casting process.

Principally, you can control the vacuum die casting process in three major ways as follows;

1. Simultaneously injecting molten metal and vacuum creation
2. Creating the vacuum inside the die cavity first and injecting the molten metal
3. Vacuum creation and molten metal injection timing regulated by sensors.

Technically, you can do vacuum die casting using any of the abovementioned approaches.

However, the generalized process entails the following;

Metal Melting

You have to melt the specific metal before starting this particular process.

It can be a simple or complex task depending on how you approach it, but the essence of melting metal is to enhance the results.

Gradual Injection Of Melt Metal

The molten metal is poured into a cylinder where it is driven inside die cavity assisted by a piston.

It is then pushed slowly under low pressure into the die cavity.

Creating Vacuum

With the assistance of a vacuum pump, the vacuum valve opens and removes air inside the die cavity.

Once the air is removed, it creates adequate negative air pressure inside the die cavity, allowing vacuum valve closure.

High-pressure Rapid Injection

Once the vacuum is created, the molten metal is fast pushed inside die cavity under intense pressure.

Since there is an already existing vacuum, the molten metal evenly spreads inside the die cavity and seals all pores and voids.

Casting Solidification And Removal

The molten metal is allowed to cool down and harden inside the die cavity.

Dies are ejected, and the finished part is taken out to allow for next casting operation.

Which Features Should You Consider In Vacuum Die Cast Parts?

Vacuum die cast component

Of course, vacuum die casting is regarded as the most suitable method for creating complex and high-precision parts.

Simply put, it implies parts derived from the process exhibit different technical features since they are quite unique.

Some notable features of vacuum die-cast parts include the following;

• Better surface finish
• Excellent thermal conductivity
• Incredible precision and dimensional stability
• Ideal thin-wall capability
• Greatly recyclable
• Outstanding corrosion resistance
• Cold formable properties for easy joining

Which Metals Are Suitable For Vacuum Die Casting?

Ideally, vacuum die casting can use different types of metals to produce desired parts.

However, each project requires a specific alloy to produce suitable results.

It is the reason you may use various metals to enable you to make the best choice for your particular product.

Nonetheless, here are the most commonly used metals in vacuum die casting process;

Aluminum

This metal exhibits some of the notable features suitable for making different products.

Remarkably, it is lightweight, offers high operating temperatures, incredible thermal conductivity, and full recyclability.

Besides, its heat dissipating properties, corrosion resistance, and strength add to its significant advantages.

It is available in several alloys, including 44300, 46000, 47100, A380, A413, B390, and A360 among others.

Zinc

It is known for its excellent dimensional accuracy, high strength, corrosion resistance, quality finishing properties, and full recyclability.

Zinc exhibits high hardness and strength making it a suitable solution and better alternative for machining, pressing, stamping, and fabricating parts.

You can find it in various alloys such as ZP2, ZP3, ZP5, Zamak 7, ZA8, and EZAC among others.

Magnesium

This metal is notable for its strength, rigidity, and recyclability, making it a suitable alloy for products where saving weight is a concern.

It guarantees immense durability and is relatively cost-effective than most vacuum die casting metals.

The common magnesium alloy often used is AZ91D, which provides an excellent combination of castability, corrosion resistance, and mechanical properties.

Which Defects Are Common During Vacuum Die Casting?

During vacuum die casting, several casting defects may take place.

Of course, it is unwarranted to have finished parts with defects since this process can also overcome them.

Such defects include the following;

Vacuum die casting defects

Blisters

These are die casting effects that often arise when heat-treating a die-cast component.

Besides, they may occur due to trapped gas pores inside the die cavity.

An ideal way vacuum die casting can eliminate these defects is by allowing heat treatment to enhance the metal’s microstructure.

Porosity

It refers to entrapment of air resulting in void space forming on the surface of a casting.

Porosity reduces the strength and deters appearance of parts significantly.

Reducing or averting this defect during vacuum die casting requires proper and early planning.

Effective communication among involved parties during part designing process also prevents it from occurring.

Cold Shuts

This defect refers to void spaces common when molten metal getting into different gates fails to merge appropriately.

Vacuum die casting is essential in reducing this defect from occurring on parts.

Misrun

Misrun occurs when molten metal fails to get into specific points in die cavity.

Often, it happens due to provision of thin walls in the design.

Vacuum die casting prevents this defect from happening by providing flexibility of wall sizes during design process.

Is There Recommended Tolerance In Vacuum Die Casting?

Not really.

A suitable tolerance in vacuum die casting process is dependent on numerous elements.

Notably, the design engineer must establish the required precisions for every die cast part.

Simply put, it is necessary to outline the precision tolerances in the agreed-upon critical points.

Nonetheless, the ideal tolerance should be +/-.0005″ based on the part size and the feature.

How Do You Increase Precisions During Vacuum Die Casting?

Essentially, vacuum die casting is an effective method for enhancing parts’ precision.

However, precision of die-cast parts is usually dependent on tooling accuracy.

Vacuum die casting enables you to incorporate relatively complex features in your design.

As such, it makes it easy to attain high precision in the specific parts you are creating.

Besides, this method prevents you from providing thin walls and undercuts in your design.

Ultimately, it increases part precision and makes it more suitable for its respective application.

Which Finishing Operations Do You Use After Vacuum Die Casting?

You can use two key post-casting finishing operations on vacuum die casting parts, and they include the following;

CNC Machining

It is a technique used for attaining vacuum die casting part precision.

This operation comes in handy, especially when the unit machining trade-off is seemingly more affordable than investing in complex die casting slides.

CNC machining is effective and produces desired finishing results within shortest time possible.

However, it requires relative knowledge and experience to execute the process to attain desired results.

Surface Finishing

This refers to different industrial processes used for altering the surface of the cast part to attain a particular property.

Essentially, this finishing operation intends to provide an additional layer on the part to enhance its efficiency, reliability, and performance.

You can also add surface finishing for cosmetic purposes on the part.

Some of the notable surface finishing options you can apply on vacuum die casting parts include the following;

• Anodizing
• Powder coating
• Mechanical finish
• Chemical finish

What Is The Cost Of Vacuum Die Casting?

Generally, vacuum die casting is more cost-effective than many types of traditional die casting methods.

However, the vacuum system is usually an integration of the traditional die casting methods.

Thus, it means there is an additional cost revolving around installation.

Nonetheless, in the long run, vacuum die casting is economical since it eliminates the need for numerous post-casting operations.

In essence, this method yields high-quality parts with enhanced mechanical properties and is free from defects.

Thus, it reduces the need for some quality control checks and mitigates wastage due to production of flawed parts.

Furthermore, the finished parts exhibit a great surface finish reducing the need for additional surface coating.

As such, vacuum die casting potentially saves money that would otherwise be spent on past-processing of resultant parts.

With all these facts taken into consideration, it is quite apparent that vacuum die casting is more economical in the long run.

Can Vacuum Die Casting Make Thin-walled Parts?

Yes.

However, the precise dimension is hugely dependent on the type of metal material you are casting.

Technically, different metals have various properties, which affect the overall tolerance of the parts.

For instance, zinc alloys can easily make thin-walled vacuum die casting parts since the material is ductile and easy to plat.

Moreover, resultant zinc alloy parts have close tolerances, which is imperative in attaining thin-walled components in this casting process.

Therefore, using right tools, machines, and correct procedure allows you to easily make vacuum die casting thin-walled parts.

How Do You Test Quality Of Vacuum Die Cast Parts?

Ordinarily, test quality of vacuum die cast parts often varies from one to another.

Of course, the essence is to ensure the parts meet a high level of end-user expectations.

The general quality tests for these parts involve the following methods;

Preliminary Tests

Preliminary tests involve visually scrutinizing the parts to ensure they are appropriately filled with metal.

Thus, some elements looked into in this case include holes, cracking, tearing, non-fills, etc.

This technique also involves meticulous inspection of each part to ensure zero distortions and bends before moving to the next quality assessment stage.

During final inspection phase, inspected parts are compared and documented to the specific casting quality control plan.

Mechanical Test

The essence of mechanical testing is to confirm whether the properties of cast parts are correct.

It affirms the part properties meet the specific mechanical requirements, and some of the mechanical tests include the following;

1. Tensile testing
2. Hardness testing
3. Load testing

Dimensional Test

It is a test to determine the specific range of values the vacuum die casting parts fall within.

This is necessary because it ensures that your parts have the right tolerance depending on your application.

The parts dimensions are verified using different tools and machines, including micrometers, plug gauges, and CMM machines among others.

Chemical Tests

Various chemical properties of the vacuum die casting parts are tested to ensure compliance with the requirements.

Analysis machines are used in these tests, such as X-ray fluorescence and spectrometer in laboratories.

Non-destructive Tests

These are specific tests done on casting parts to determine quality without necessarily destroying the part.

The common non-destructive quality inspection tests include the following;

• Magnetic particle inspection
• Liquid penetrant testing
• Radiographic inspection

Which Parts Can You Make Through Vacuum Die Casting?

You can make thousands of parts through vacuum die casting process to use in different applications.

Some of these parts include the following;

• Automobile engine component
• Radar housing
• Medical operation holder
• Medical heat sink
• Medical frame component
• Intake tube compartment
• Heatsinks
• Motor cover
• Engine filter component
• Engine mountings
• Automobile oil sump

What Is The Production Lead Time For Vacuum Die Casting?

Vacuum die casting process

Ordinarily, the actual production lead time for this process varies based on different factors.

In most instances, the simplicity or complexity of the part determines the actual turnaround for this process.

Besides, different manufacturers have varied timelines for producing vacuum die casting parts.

In essence, the machine and related equipment they have for this process would determine how fast they can produce the parts.

Also, the actual parts quantity you are vacuum die casting also influences the overall production lead time.

Technically, this process is quite fast; thus, with proper planning and organization, you can attain rapid production.

Therefore, you need to inquire and confirm with your preferred manufacturer to provide actual turnaround time based on various prototype assessments.

How Can You Reduce Gas Porosity During Vacuum Die Casting?

During die casting, voids or gas pores tend to form on the surface of the part material.

The main cause of porosity in cast parts is entrapment of gas or air inside die cavity.

However, vacuum die casting process injects molten metal into die under high pressure.

The process also creates a vacuum in both the mold cavity and short sleeve before injection shit takes place.

While at it, almost all air is evacuated positively from mold and vacuum maintained until completion of injection cycle.

In essence, this reduces significant gas porosity in the casting and leads to subsequently enhanced density and tensile strength of the part.

How Can You Improve Efficiency Of Vacuum Die Casting?

Vacuum die cast part

Ideally, proper planning is a core element in enhancing efficiency and attaining better results in vacuum die casting.

It is quite broad and involves the following specifics;

1. Automation – It would be ideal to go for advanced equipment for vacuum die casting process. Hi-tech machines reduce downtime, costs and enable you to attain quality parts.
2. Simulation – Ideally, it is advisable to conduct a test run to determine all the vital aspects that require attention and adjustment before the actual process. It enables the designers to identify and fix all the critical elements necessary in the process.
3. Scrap reduction – You can attain this through proper planning of the entire production process. Thus, it would be necessary to conduct product and process analysis focusing on causes of scrap.

Apart From Vacuum Die Casting, Which Other Die Casting Technologies Can You Recommend?

Other technologies include:

Sand Casting

You may consider this method as an alternative for producing casting parts.

Technically, this method entails use of a pattern that is an imitation of the finished casting.

Therefore, you can easily use any pattern by pressing into a fine sand mixture to form a mold where the molten material is poured.

However, sand casting technique forms a slightly larger pattern than the actual casting part that is produced.

In essence, it enables the molten metal to shrink during cooling and solidification.

This alternative casting method is slower than vacuum die casting but relatively cost-effective, thus ideal for small-scale part production.

You can also use it to make complex designs or when in need of large castings.

Precision Casting

In some cases, it is referred to as investment casting or lost cast waxing.

It entails forming a wax pattern similar to the shape of preferred final product.

This wax shape is attached to a component to a tool and repetitively plunged into liquid ceramic until it solidifies.

Molten metal solidifies within a mold before it is shattered and forms an entire cast metallic part.

Precision casting is a suitable vacuum die casting alternative for relatively low volume production.

Are Vacuum Die Cast Parts Durable?

Yes.

The metals used for producing vacuum die cast parts are naturally strong.

Moreover, such metals feature various properties that enable the final product to withstand numerous mechanical and physical conditions.

For instance, the alloys combine different features, including corrosion resistance, rigidity, toughness, bearing performance, etc.

Therefore, the resultant parts can endure aggressive and abrasive conditions without wearing out easily.

Simply put, vacuum die cast parts exhibit incredible durability in different applications they are used.

What Are The Benefits Of Vacuum-Assisted Die Casting?

It is advantageous in enhancing the overall efficiency of the process in the following ways;

• Preventing shrink marks
• Enhances production of weldable die cast parts
• Enhancing the static-dynamic and mechanic features
• Prevents air entrapment
• Enhances surface finish quality
• Facilitates production of die cast parts suitable for heat treatment.

Which is Industries Use Vacuum Die Casting?

Technically, vacuum die casting is used in a wide range of industries where a high quality of parts for products is a significant concern.

The major industries utilizing this benefit more include the following;

• Military
• Medical
• Electronics
• Aerospace
• Telecommunication
• Marine

Does Vacuum Die Casting Increase Weldability?

Yes.

Ordinarily, weldability is an element principally limited to metals.

However, this feature is not same for all metals.

It means in some metals; it is easier to weld than in others.

Technically, the weldability of a metal is based on its mechanical and microstructure properties.

Vacuum die casting enables the part to have a better microstructure and enhances parts’ integrity.

In essence, this increases die casting weldability without necessarily using expensive materials with higher weldability.

Should You Heat Treat Vacuum Die Cast Parts?

Yes.

Most resultant vacuum die casting parts are given heat treatment.

Primarily, heat treatment refers to a process of changing mechanical properties of the metal.

Heat treatment can manipulate diffusion and cooling rate within the microstructure of the metal.

You should consider this process of vacuum die cast parts since it enhances ductility, strength, hardness, and elasticity.

Thus, it enables the metal to attain superior mechanical using inexpensive metals.

Additional Resources:

Die Casting Mold

Aluminum Die Casting

Zinc Die Casting

Magnesium Die Casting

Titanium Die Casting

Copper Die Casting

Hot Chamber Die Casting

Cold Chamber Die Casting

Low Pressure Die Casting

Gravity Die Casting

For any questions or inquiry about vacuum die casting, contact us now.