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This differential pressure is what forces the molten metal from below the surface into the mold cavity. While gravity pouring has its advantages, within some geometries it can result in a turbulent metal flow that can lead to entrained gas. The objective of vacuum casting is to control the metal flow as much as possible for a tranquil mold fill. For metal castings that call for a sound, consistent integrity, vacuum casting may deliver.
The following advantages of vacuum casting lend the process to precision applications: flow rate of molten metal into the mold cavity can be accurately controlled, improving overall metal casting soundness; flow rate of the molten metal can be increased to fill the mold cavity more quickly than with gravity pouring, resulting in the fill out of thinner casting sections; metal drawn into the mold cavity is from below the surface of the molten metal bath, avoiding slag and inclusions; critical metal temperature variations can be more consistently controlled since the mold is taken to the furnace rather than vice versa; good surface finish; excellent dimensional tolerances; it is often easier to automate than gravity pouring.
This method of vacuum casting is used in the permanent mold, die casting, investment casting and sand casting processes. Choosing the molding method for vacuum casting usually follows the same guidelines as choosing the molding method for typical gravity pouring. Aurora Metals has been utilizing a vacuum to draw metal into a mold since the s. Historically, the facility only had been able to use its process with copper-base alloys and some other nonferrous alloys because the firm was using steel molds.
But, two years ago, the metal caster began developing a method to use its vacuum casting equipment to accommodate sand molds and now Aurora Metals can vacuum-cast stainless steel components. Vacuum or vacuum-assisted casting is sometimes referred to as countergravity casting. Countergravity casting can be performed using low pressure, electromagnetic pumping or a vacuum.
Ideal castings for the highly automated countergravity-poured investment casting process have thin walls and are of high volume. Markets include automotive, aerospace, golf clubs, military, land-based gas turbines and medical applications. After the casting is filled and the gates are solidified, the vacuum is released, causing the metal in the sprue and gating to return to the furnace. This results in a better metal yield with less gating to cut off. The disadvantage of the vacuum in this method is that the vacuum must be left on until the gating has solidified.
V-process molds, which often are gravity poured, are given their shape with the use of a vacuum. This method, which was brought to the U. A thin sheet of plastic film is heated and vacuum-fitted to the pattern, covering it. A flask is placed around the film-covered pattern and filled with a fine, dry unbonded sand.
Vibration compacts the sand to fill in the crevices and reach maximum bulk density. A second sheet of plastic film is placed on top of the mold, and the vacuum is released from the pattern and applied to the flask containing the sand. The flask is stripped of the pattern, ready for pouring. The other half of the mold is produced in a similar manner, then aligned with the first half.
The cope and drag assembly remain under vacuum while the molten metal is poured. The plastic film melts and is replaced by the metal. After the metal has solidified, the vacuum is released and the sand falls away from the casting. Advantages of the V -process include: zero degree draft; wall thicknesses of 0. Enter a phrase to search for:. Search by. Full text Keywords. Headings Abstracts. This article belongs to a series of articles.
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Top review from the United States. There was a problem filtering reviews right now. Please try again later. Vacuum chamber holes in the rubber mat must be plugged. Verified Purchase. I use the device for jewelry casting. It has worked well for my needs. See all reviews. Exclusive items from our brands. Only 1 left in stock - order soon. Pages with related products. See and discover other items: cast mold , casting molds for metal , metal casting molds , molds for metal casting , Best Rated in Metal Casting Machines , Vacuum Bell Jars.
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