17 Fondarex FSA Forum

Technical Considerations on the Application of Vacuum
Technology for High Quality Die Casting Parts
Jan Emmenegger
Engineering Director
1st International Forum, IDRA and Foundry Star Alliance,

March 1-2, 2016, Monticelli Brusati, Italy
Content
1. Company
2. Introduction of High Quality Vacuum Die Casting Parts
3. The Vacuum Technology in the Pressure Die Casting Process
4. Vacuum Application Study
5. Aluminum and Moisture / Humidity Sensor
6. Services and Products
7. Vacuum Process Control / Data Transfer, Industry 4.0
8. Practical Examples
COPYRIGHT © 2016 FONDAREX SA 1st International Forum, IDRA and Foundry Star Alliance, March 1-2, 2016, Monticelli Brusati, Italy 2
1. Company
 Founded in 1946 as a pressure die casting foundry

 Inventor of the vacuum technology for pressure die casting (1952) and
plastic injection molding (2002)
 35 collaborators, 25 representatives and more than 1000 customers
over 50 countries
1. Company
FONDAREX has implanted the first vacuum system into a die casting mold
back in 1952. The target was to remove enough air out of the cavity, to reduce
porosity in the casted part, to have a better availability for filling and getting a
better alloy structure.
The vacuum systems have been developed a lot since, but the basic stays
exactly the same; creating a vacuum in the die cavity for better castings.
Furthermore, the know-how and the experience have increased a lot as well.
Therefore, FONDAREX became the right partner for the high

quality pressure die casting process.
COPYRIGHT © 2016 FONDAREX SA IDRA: 1st congress 01 and 02. March 2016 4
1. Company
The FONDAREX World

 Consulting
 Vacuum project recommendation
 Vacuum application study
 Vacuum system
70TH ANNIVERSARY
 Vacuum valve 1946 2016
 Chill-block
 Technical support
 Spare parts
 Training and forum
2. Introduction to High Quality Vacuum Die Casting Parts
The challenge and requirements of new high pressure die castings:

 Porosity free
 Weldable
 Integration of different parts in one
 Some of the parts do show complex geometries
 Perfect crash performance
 Weight reduction
 Thin wall characteristic with thicker sections
 High mechanical performance
 Heat treatable
 Tight tolerances
 Nice surfaces
2. Introduction to Thin Wall / Structural Parts
Benefits of a new design and high pressure die casting:

 Number of parts: 30% reduction
 Welding length: 30 – 50% reduction
 Weight: 10% reduction
 Cost: 12 – 30% reduction
(All numbers above are based on
conventional steel sub-frames)
 Improvement of vehicle handling response
 Crash test prove
 Reduction of vehicle noise and vibration
Important points to be considered by using the vacuum technology

in structural pressure die casting:
 Understanding of the vacuum technology
 Choice of the suitable equipment, tank – tool ratio about 1:100 min
 Use of the necessary interconnections between die cast cell and vacuum
equipment
 Design of a precise die
 Control of the vacuum cycle
 Recording the vacuum level (pollution level, vacuum curve, profile control
value)
 Continuous training on manpower
 Maintenance of the equipment
These are the influences to control in order to get the required vacuum level
in continuous production:
 Tool tightness (closing)
 Tool cleanness (lubricants, water, flash)
 Piston speed used in the casting process
 Plunger tightness in the shoot sleeve
 Ratio of tank and tool volumes
 Vacuum channel lengths and cross-sections (resistance)
 Vacuum valve or chill-block size (capacity)
 Attachment of the casting part by vacuum gates/channels
 Surface quality of the die, vacuum device, hoses (machining, polishing)
 Performance and shape of the vacuum equipment
It is important that in the production process vacuum levels below 100 mbar can
be achieved:
The air extraction of a die including the shot sleeve adaption:
 The vacuum application starts with

the shot sleeve
 If possible do not use a counter
piston (because of turbulences, first
phase velocity settings and over
heating)
 The design of the runner is the
key point of the application
 The choice of the right evacuation
system will guarantee the adequate
vacuum level in the cavity
Since the FONDAREX vacuum systems can control both

vacuum valves and chill-blocks, it is possible to use both types
in the same die/application.
 Recommendations
 Avoid all turbulences in
the shot sleeve
 Use fixed and mobile
die halves for the most
dynamic runner design
 The basics for the vacuum
design should be without
overflows or with small
ones only
FONDAREX is recommending rather small overflow

volume for the following reasons:
 Less alloy passing the die cavity, less die wear
 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
 If a modification is necessary, it is much easier to
open a small overflow than to weld a large one
5. Aluminum and Moisture
It is possible that next to shrinkage If those are found in certain areas,

and gas porosity nanoscale the ductility of the part will decrease.
properties of oxide layers will
appear in the metal structure.
5. Aluminum and Moisture
5. Humidity Sensor, Patented
Capabilities
 Reliable measurement of the humidity
during the evacuation process
 Possibility to detect leaks instantly
 Well designed against pollution
(less maintenance)
Challenges
 Management of reliable and
precise measurement
(during a short evacuation time)
 Management of the very fast pressure
and temperature and
flow variations
5. Humidity Sensor, Patented
The humidity sensor is compatible with the

HIGHVAC PREMIUM and the HIGHVAC ULTIMATE Series
6. Services
 Reactive and professional customer support worldwide

 Periodic vacuum trainings on customer’s site or at Fondarex
 Large product range with high flexibility regarding custom-made solutions
 Great experience and know-how in vacuum die casting
6. Products
HIGHVAC ECONOMY 1C
HIGHVAC PROGRESS 2C
HIGHVAC PREMIUM 2C
HIGHVAC ULTIMATE 4C
6. Products
HIGHVAC ULTIMATE 4C
With 4 independent vacuum channels

and a 2’000 liter tank
6. Products
6. Products
SUPERVAC
MONOVAC
CHILL-BLOCK
7. Vacuum Process Control
Vacuum measurement per channel
Pollution control per channel

Profile control per channel
Pollution control per channel

Profile control per channel
Evacuated air volume measurement
Leak test with vacuum or pressurized air
Alarm management
Log Data
 Straight to Excel, straight to work
7. Data Transfer
Profinet, Profibus, Ethernet

 Your data, your path
7. Data Transfer
Profinet, Profibus, Ethernet

 Your data, your path
Customer: BMW
1st Price at Euroguss 2014
Country: Germany
Part Name: Rear Axle Carrier BMW i3
Number of Cavities: 1
Vacuum Unit: HIGHVAC ULTIMATE 4C 2000
Customer: TESLA
Country: USA
Part Name: Shock Tower
Customer: HANDTMANN
Country: Germany
Final User: BMW
Part Name: Shock Tower
Customer: CO.STAMP
Country: Italy
Final User: LAMBORGHINI
Part Name: HURICAN REAR GRID
Vacuum Unit: HIGHVAC PREMIUM 2C 800
Conclusion
The pressure die casting process for structural parts must be planned and
controlled very well. Each sector and process must be made better in
comparison with the traditional die casting process.
Regarding the vacuum process, it is very important to get a well sealed die,
which does not flash during the casting process.
It must be possible to reach vacuum levels below 60 mbar.

For that, it is very important to manage a clean overall vacuum die casting
process.
Thank you for your Attention
Jan Emmenegger
Engineering Director

17 Fondarex FSA Forum

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Technical Considerations on the Application of Vacuum

Technology for High Quality Die Casting Parts

1st International Forum, IDRA and Foundry Star Alliance,

2. Introduction of High Quality Vacuum Die Casting Parts

3. The Vacuum Technology in the Pressure Die Casting Process

4. Vacuum Application Study

5. Aluminum and Moisture / Humidity Sensor

6. Services and Products

7. Vacuum Process Control / Data Transfer, Industry 4.0

 Founded in 1946 as a pressure die casting foundry

Therefore, FONDAREX became the right partner for the high

The FONDAREX World

The challenge and requirements of new high pressure die castings:

Benefits of a new design and high pressure die casting:

Important points to be considered by using the vacuum technology

 The vacuum application starts with

Since the FONDAREX vacuum systems can control both

FONDAREX is recommending rather small overflow

It is possible that next to shrinkage If those are found in certain areas,

The humidity sensor is compatible with the

 Reactive and professional customer support worldwide

With 4 independent vacuum channels

Vacuum measurement per channel

Pollution control per channel

Pollution control per channel

Evacuated air volume measurement

Leak test with vacuum or pressurized air

Profinet, Profibus, Ethernet

Profinet, Profibus, Ethernet

It must be possible to reach vacuum levels below 60 mbar.

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