Vacuum Die Casting
Vacuum Die Casting
At Aurora Metals Division
At Aurora Metals Division, we take pride in our expertise in vacuum die casting, a process we pioneered and perfected over 95 years ago. This innovative technique has revolutionized the casting of high-strength, corrosion-resistant aluminum bronzes, and has since proven to be an economical solution for producing complex, high-quality parts that were once challenging to manufacture.
Our Specialty: Non-leaded Brass and Bronze Alloys
Our specialty lies in the vacuum die casting of Non-leaded brass and bronze alloys. This advanced process ensures the production of high-density uniformly sound castings that are ideal for critical applications across various industries. The unique properties achieved through the vacuum die casting of aluminum bronze alloy’s make it possible to create parts that were previously made from steel, significantly reducing the need for extensive secondary machining.
The Vacuum Die Casting Process
The vacuum die casting process at Aurora Metals Division is a carefully controlled and highly efficient operation. Here's how it works:
- Die Preparation: We begin with a metal die enclosed in an airtight bell housing, also known as a receiver. This housing has two crucial openings: the sprue at the bottom for molten metal entry, and the vacuum outlet at the top.
- Vacuum Creation: The sprue opening is submerged below the surface of the molten metal in the crucible. We then draw a vacuum within the receiver, creating a pressure differential between the die cavity and the molten metal.
- Metal Injection: The pressure differential causes the molten metal to flow up the sprue and into the die cavity. This method ensures that only pure alloy, free from oxides and dross, enters the die cavity, resulting in clean, sound castings with minimal foreign materials.
- Solidification and Ejection: Once the metal solidifies, we remove the die from the receiver, open it, and eject the casting. This cycle is repeated for each shot, with each cycle producing one or several castings, depending on the number of cavities in the die.
Advantages of Our Vacuum Die Casting Process
- Precision Control: By controlling the vacuum, we can vary the pressure differential between the die cavity and the molten metal. This allows for differential fill rates necessitated by part design and gating requirements, resulting in tight control of the fill rate and directly influencing the soundness of the casting.
- Reduced Defects: Through proper part design, die design, and the use of our vacuum die process, we can greatly reduce or eliminate voids, shrinks, and gas pockets in critical areas of the casting.
- Superior Material Properties: The vacuum process ensures that only pure alloy enters the die cavity, producing castings with enhanced strength, appearance, and machinability.
- Near Net Shape Casting: Our process allows for the production of parts with complex geometries and tight tolerances, often eliminating or significantly reducing the need for secondary machining operations.
- Material Efficiency: The vacuum die casting process minimizes waste and allows for the efficient use of materials, making it a cost-effective solution for many applications.
Applications and Industries
Our vacuum die cast parts find applications in various industries where high performance and reliability are crucial. Some common applications include:
- Pump impellers
- Valve bodies and components
- Electrical connectors and components
- Aerospace and defense parts
- Marine hardware and fittings
Why Choose Aurora Metals Division for Vacuum Die Casting?
- Expertise: With over 95 years of experience in vacuum die casting, we have refined our process to achieve optimal results consistently.
- Quality Assurance: Our rigorous quality control measures ensure that each part meets or exceeds the required specifications.
- Material Knowledge: Our deep understanding of brass and bronze alloys allows us to suggest the best material for each application.
- Custom Solutions: We work closely with our clients to develop custom solutions for their unique casting challenges.
- Advanced Technology: We continually invest in state-of-the-art equipment and technology to maintain our position as industry leaders.
At Aurora Metals Division, we are committed to pushing the boundaries of what's possible in vacuum die casting. Whether you need a single prototype or high-volume production, our team is ready to deliver solutions that meet and exceed your expectations. Experience the Aurora Metals difference – where innovation meets precision in every cast.