Multi-step Vacuum Technology for

High Pressure Die Casting (HPDC)

Vacu
[vk.ju tu:]

A newly developed process by

Pfeiffer Vacuum GmbH

Pfeiffer Vacuum 2007 Business Unit Systems, Volkmar Gibietz, 2007-04-24 Page 11
 Pfeiffer Vacuum 2007 Business Unit Systems, Volkmar Gibietz, 2007-04-24 Page 12
 High Pressure Die Casting Machine

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 High Pressure Die Casting Machine Schematics

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 HPDC Sleeve and Parts

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 Vacuum for HPDC

Why vacuum? Does it always make sense?

z Classical HPDC : more then 30% to 50% enclosed air
- Nitrogen
- Compressed to small volume

z Vacuum
- when 100 mbar would be reached in the die f.e. 10%
- if something goes wrong, no air can escape
- Which pressure is realy achieved in the die ?
- How reliable and stable is the process?

Pfeiffer Vacuum 2007 Business Unit Systems, Volkmar Gibietz, 2007-04-24 Page 16
 Applications in HPDC

Parts with complex geometry

Heat treatable castings

Weldable castings

Later:
Normal parts with better quality and higher outputs?

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 Examples for valves and pistons

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 Old: Standard Vacuum System

Limited area
Blocking-effect

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 Old: Standard Vacuum System

Limited time
No equilibrium

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 Old: Standard Vacuum System

Large influence
from leakage on
equilibrium

Pfeiffer Vacuum 2007 Business Unit Systems, Volkmar Gibietz, 2007-04-24 Page 21
 Old: Standard Vacuum System

Measurement

Pressure in the
die ???

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 Old: Standard Vacuum System

Process-
stability
???
Process-
control

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 Old: Vacuum System with metal-dosing

More time
Nearer at
reachable
equilibrium

Pfeiffer Vacuum 2007 Business Unit Systems, Volkmar Gibietz, 2007-04-24 Page 24
 Old: Vacuum System with metal-dosing

Limited area
Blocking-effect

Pfeiffer Vacuum 2007 Business Unit Systems, Volkmar Gibietz, 2007-04-24 Page 25
 Old: Vacuum System with metal-dosing

Measurement

Pressure in the
die ???

Pfeiffer Vacuum 2007 Business Unit Systems, Volkmar Gibietz, 2007-04-24 Page 26
 Old: Vacuum System with metal-dosing

Large
influence from
leakage on
equilibrium
Elaborate
sealing

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 Old: Vacuum System with metal-dosing

vulnerable
dosing system

Pfeiffer Vacuum 2007 Business Unit Systems, Volkmar Gibietz, 2007-04-24 Page 28
 New: Multi-step Vacuum System
invented by Pfeiffer Vacuum (Principle)

Pfeiffer Vacuum 2007 Business Unit Systems, Volkmar Gibietz, 2007-04-24 Page 29
 New: Multi-step Vacuum System
invented by Pfeiffer Vacuum (Principle)

Smaller volumes

Pfeiffer Vacuum 2007 Business Unit Systems, Volkmar Gibietz, 2007-04-24 Page 30
 New: Multi-step Vacuum System
invented by Pfeiffer Vacuum (Principle)

Bigger Area
Equilibrium is reached in very
short time and has lower value
Less influence from leakage

Pfeiffer Vacuum 2007 Business Unit Systems, Volkmar Gibietz, 2007-04-24

Page 31
 New: Multi-step Vacuum System
invented by Pfeiffer Vacuum (Principle)

Dosing amount and

vacuum are
independent

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 New: Multi-step Vacuum System
invented by Pfeiffer Vacuum (Principle)

Process-stability:
Two steps / lower equil. Reached, 2nd
order stability
Less influence leakage

Pfeiffer Vacuum 2007 Business Unit Systems, Volkmar Gibietz, 2007-04-24 Page 33
 New: Multi-step Vacuum System
invented by Pfeiffer Vacuum (Principle)

Process-control
-Before production starts
-During production

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 Pfeiffer Vacuum 2007 Business Unit Systems, Volkmar Gibietz, 2007-04-24 Page 35
 Pfeiffer Vacuum 2007 Business Unit Systems, Volkmar Gibietz, 2007-04-24 Page 37
 Results

< Normal vacuum

Multi-Step Vacuum >

Vacu
Pfeiffer Vacuum 2007 Business Unit Systems, Volkmar Gibietz, 2007-04-24 Page 38
 Results

< Normal vacuum

Multi-Step-Vacuum >
Vacu
Pfeiffer Vacuum 2007 Business Unit Systems, Volkmar Gibietz, 2007-04-24 Page 39
 Results Comp. X-Ray
Multi-Step Normal Without

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 First trials with Pilot Plant in the HPDC technology centre of

Test conditions:
HPDC-Machine 2000 t

Simple sealing in closing surface

(parting line)

Second step over piston-type vents with

venting surface area 2x 65 mm2

Pfeiffer Vacuum 2007 Business Unit Systems, Volkmar Gibietz, 2007-04-24

Page 41
 Glhtest - Glowtest

Standard-Vakuum / Standard Vacuum 2 Stufen-Vakuum / 2-Step Vacuum

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 Glhtest - Glowtest

Standard-Vakuum / Standard Vacuum 2 Stufen-Vakuum / 2-Step Vacuum

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 Glhtest - Glowtest

Standard-Vakuum / Standard Vacuum 2 Stufen-Vakuum / 2-Step Vacuum

Pfeiffer Vacuum 2007 Business Unit Systems, Volkmar Gibietz, 2007-04-24

Page 44
 Pfeiffer Vacuum Vacu2

Versuche 04/2005 Trials

Pilotanlage Pilot plant
bei at

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Versuchsbedingungen Test conditions

Projekt tiefes Vakuum und Legierungsentwicklung

Druckgussanlage 700 t
Ohne Abdichtungen in der Form
Zweite Stufe ber Waschbrett-Ventil 90 x 0.9mm

Project low vacuum and alloy-development

High pressure die casting machine 700 t

Without sealing in the die
Second vacuum-step over Washboard-Vent 90 x 0.9mm

Pfeiffer Vacuum 2007 Business Unit Systems, Volkmar Gibietz, 2007-04-24 Page 46
Vergleich Mikrostruktur / Comparisson microstructure

2 Stufen-Vakuum Standardvakuum Ohne Vakuum

2 Step-Vacuum Standardvacuum Without Vacuum

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Mechanische Eigenschaften Mechanical Properties

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 Measurements die side
good sealing

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 Measurements die side
bad sealing

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 Measurements sleeve side
bad sealing

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 Measurements 2 Step
bad sealing / poor throughput valve

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 Messkurven
Produktion

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 Messkurven
Produktion

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 Korrelation
Prozessparameter / erreichter Enddruck (zurckgerechnet)

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 Vacu - System (patents pending)

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 Control Panel

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 Brochures / Literature

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Brochures / Literature

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Vacu - Market Introduction
Press Release

Pfeiffer Vacuum 2007 Business Unit Systems, Volkmar Gibietz, 2007-04-24

Page 62
 Thank you !

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