• Transactions of Materials Processing
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• v.21 no.3
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• pp.195-201
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• 2012

A vacuum ladling die casting system is suggested as a means to obtain a high vacuum level. A high vacuum of 17.8 mmHg is obtained by sealing the inner space of the mould. The sample product is a rear-head housing for an auto-compressor, and the die-casting with 6-cavities was conducted. The flow analysis shows that the filling speed during vacuum ladling is faster than for a non-vacuum system. The air holes in the sample product were too small to be seen with the naked eye in X-ray films. Density tests show that the high vacuum ladling system reduces the internal porosity as much as 57.8% when compared to the non-vacuum system. A defective rate of only 0.17% was found from leak testing. The results of this research prove that the high vacuum die-casting process is useful for manufacturing of aluminium components under high internal pressure.

• Journal of the Korean Society of Industry Convergence
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• v.21 no.1
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• pp.1-8
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• 2018

The purpose of this study is to develop a high-strength, high-toughness, thin-walled aluminum shock absorber housing product by applying a high vacuum die casting method to improve internal gas defect and formability. The analysis program dedicated for the casting was used because it was too costly and time-consuming to adopt the gating system design. The final casting plan was designed based on the flow pattern of the material filled into the mold and the result of air pressure and air pocket after the material was completely filled in the mold. Gaty shape was designed as a split type. The runner was designed to have the same shape as the initial inlet curve of the cavity, and the flow of the molten metal was prevented from turbulent flow. The most favorable results were obtained when the injection speed was $V_2=4.0m/s$. Defects on pores were reduced by applying high vacuum level inside the mold.

• Transactions of the Korean Society of Automotive Engineers
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• v.20 no.4
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• pp.52-59
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• 2012

The subframe has been generally manufactured by using stamped steel material. Recently, automotive designers are considering aluminum as lightweight material. This paper describes the development process of an aluminum subframe which is made by high level vacuum die casting process, which is beneficial for minimizing gas contents and material properties. The weight of manufactured subframe is reduced by 4kg with the comparison of steel subframe. The aluminum subframe is packaged for the current vehicle layout and the imposed requirement is to attain a better structural performance that is evaluated in terms of mounting stiffness, noise and vibration, and endurance performance. The NVH evaluation results show that sound level is decreased by 8dB with the help of high roll-rod mounting stiffness as well as high structural modes.

• Journal of Korea Foundry Society
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• v.20 no.3
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• pp.181-187
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• 2000

There are two types of vacuum die casting, one is known as the chill block method, and the other is the valve block method. Efficiency of the valve block method is better than the chill block method. However purchasing and maintaining cost of the former one is very high, the latter method is popular in many small and medium die casting shops. Simple evacuation system using chill vent was prepared to investigate the effect of the air pressure, hose length and chill vent type on the pressure change in die cavity in this study. The rate of evacuation was influenced by the evacuation method, chill vent condition and hose length. Evacuation time became longer and vacuum level lower when evacuating cavity via chill vent. It took a longer time to evacuate the cavity when a longer hose was used. Vacuum level in the cavity also decreased with increase in hose length.