ALUYONIX Precision Die Casting
CASTING PROCESS METHODOLOGY

Vacuum Die Casting

Sub-30 mbar cavity evacuation eliminating blister defects and enabling weldability.

Process Metallurgy & Overview

Vacuum Die Casting integrates high-capacity evacuation valves that draw sub-30 mbar vacuum across the entire die cavity and shot sleeve in milliseconds just before injection. This removes 95%+ of trapped air, completely eliminating blister porosity and enabling weldability and T6 heat treatment.

Working Principle & Operational Steps

1Vacuum valve activates as plunger passes the pour hole, evacuating air and vaporized lubricant.
2Ultra-dense molten metal enters an airless void, eliminating back-pressure.
3Mechanical chilling block or rapid hydraulic valve seals vacuum circuit before metal touches sensors.
4Castings achieve zero gas porosity, allowing 500°C solution heat treatment without surface blistering.

Technical Parameter Specifications

Clamping Force
400T – 2,500 Tonnes
Wall Thickness
1.5 mm – 10.0 mm
As-Cast Tolerance
±0.03 mm
Cycle Rate
30 – 65 shots/hr
Surface Finish
Ra 1.6 µm
Primary Alloys
AlSi10MnMg, A356

Ideal Applications

  • Automotive shock towers and suspension damper housings
  • Weldable structural vehicle spaceframe nodes and B-pillars
  • Crash-relevant battery tray perimeter side-members
  • Hermetic pressure-tight refrigerant manifolds

Key Advantages

  • 100% blister-free surface enabling T6 solution heat treatment for 200% higher elongation
  • Allows structural laser and MIG welding with zero pinhole defects
  • Significantly higher fatigue strength and crash impact energy absorption
  • Drastically reduced scrap rates in high-pressure leak testing

Engineering Trade-offs

  • Requires specialized high-maintenance vacuum die seals and vacuum chill-blocks
  • Precision tooling alignment required to maintain absolute vacuum seal

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