Vacuum die casting Professional vacuum makes the difference in die casting

Editor: MA Alexander Stark

Turkey — In order to realize complex projects of satisfactory quality in die casting, the use of the right technological equipment is essential. This article presents a statement from Celikel Die Casting, which was created in cooperation with Fondarex, a specialist in vacuum technology.

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With Fondarex as a partner, Celikel Die Casting focuses its business on the automotive industry.
With Fondarex as a partner, Celikel Die Casting focuses its business on the automotive industry.
(Source: Public Domain / Pixabay )

Founded in Istanbul in 1968, Çelikel has achieved a stable growth over the past decades and has established its reputation as a reliable supplier for the rapidly changing global automotive industry. The experts share their knowledge and experience with their customers with whom they fully cooperate in design and product development prior to production. With their extensive design knowledge, they ensure efficient production while maintaining a competitive edge in the market. Today, the manufacturer continues to support the automotive industry by combining a keen business sense based on communication and cooperation. This philosophy goes back to the company founder, the late Osman Deniz, who believed in creating a sustainable world in every aspect.
Celikel's main product groups are:

  • Structural components (BIW)
  • Powertrain products
  • E-mobility components

The company's product groups are in casting and machining operations with a state of the art technological machine park and equipment. 25 DCM with a clamping range of 560 t — 2200 t and 3 axis, 4 axis and 5 axis machining centres and all technological equipment such as Fondarex vacuum units with humidity sensors/jet coolers/squeeze pins etc. maintain a sustainable production quality for each single part. Thanks to the Çelikel Visual Production system, automated data collection corresponding quality/efficiency/performance/scrap ratios ensure high efficiency and allows the production of 15,000 t/ 30 million products per year.

Vision of nowadays industry

Operating in the die casting sector for 15 years, it is very easy to see and note that quality requirements rapidly increased while costs had to be dramatically reduced, the experts note. Car manufacturers try to combine two or three parts into one by creating new designs. The aim is to reduce mould investment costs/ reduce assembly operations in the line/ easy management of stocks etc. From the die casting point of view; various type of complex projects are the result. In this context, technological equipment usage becomes very significant because the rigidity of the die casting machine is not the only aspect that needs to be considered in order to ensure sustainable product quality.

Why is a professional vacuum required?

Vacuum die casting is the key factor to eliminate positive air pressure in front of the molten metal. This results in smooth filling and better flow results. In addition, evacuation of the air inside the cavities yields significant porosity enhancement. Jet cooling/squeeze pin addition and vacuum adaptation to the process are the key factors to meet customer requirements.

In e-mobility product casting, filling should be smooth, ingate velocities and intensifier pressure should be as low as possible to delay tool distortion. Even a 0,05 mm burr could create a short circuit while product is in function. In this case, positive air pressure in front of the molten metal should be entirely removed to let the molten metal fill the cavity without problems.

In structural component casting, filling should be smooth but from the first phase to the end of filling, no air gaps should be enclosed in the molten metal. Not only for visual faults such as blistering after heat treatment; but also, for safety reasons as porosities will create less bending/yield/tensile strength values.

The image on the left shows results without vaccum process; the image on the right shows results vacuum operation activated.
The image on the left shows results without vaccum process; the image on the right shows results vacuum operation activated.
(Source: Celikel Die Casting)

Why was Fondarex chosen as vacuum partner?

Fondarex is the only vacuum system that Çelikel choose as a solution partner. There are plenty of reasons the company states:

  • Best price/performance unit in the market
  • Effective and trained after sales service
  • Easy to perform maintenance activities
  • Easy to discuss engineering solutions
  • A strong company who is in the very centre of die casting industry
  • User friendly interface

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