• Journal of the Korean Society for Precision Engineering
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• v.26 no.3
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• pp.88-97
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• 2009

The vacuum die casting techniques can diminish the porosity of products and provide better surface appearance by the ordinary high pressure die casting process. The vacuum system can also reduce the cold laps in the die casting process and minimize the overflow pockets of the die. The vacuum system does not need high pressures to die cast compared to the ordinary die casting process, and so enables die casting of large parts for a given machine size. Parts made by the vacuum system have higher strength and more elongation than parts made by the ordinary die casting systems. In this paper, we designed and produced the Magnesium seat frames using the vacuum die casting processes. The new Magnesium seat frame was designed to satisfy safety regulations. Some safety test procedures of the seat frame were simulated by the finite element method. We obtained 10% weight reduction by design modification of seat frames compared to the current model. Flow simulations were carried out to minimize the trial and error in producing the parts. The die casted parts using vacuum systems resulted in better mechanical characteristics and no defects compared to those without vacuum systems.

• Transactions of Materials Processing
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• v.8 no.5
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• pp.491-497
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• 1999

The effect of partial squeeze on the quality of casting products in the vacuum die casting was investigated to make defect free casting products with excellent mechanical properties. The partial squeeze and vacuum die casting process was industrially implemented in making reaction shaft support which was made of a hypereutectic Al-15%Si alloy. To combine squeezing and vacuum effects, the plunger injection system was designed and attached on the chill vent type vacuum machinery system. The combination of vacuum effect before injection and partial squeezing effect after injection resulted in defect free die casting products. The uniform distribution of fine eutectic and proeutectic Si obtained from trial process also provided excellent mechanical properties.

• Transactions of Materials Processing
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• v.21 no.3
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• pp.195-201
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• 2012

A vacuum ladling die casting system is suggested as a means to obtain a high vacuum level. A high vacuum of 17.8 mmHg is obtained by sealing the inner space of the mould. The sample product is a rear-head housing for an auto-compressor, and the die-casting with 6-cavities was conducted. The flow analysis shows that the filling speed during vacuum ladling is faster than for a non-vacuum system. The air holes in the sample product were too small to be seen with the naked eye in X-ray films. Density tests show that the high vacuum ladling system reduces the internal porosity as much as 57.8% when compared to the non-vacuum system. A defective rate of only 0.17% was found from leak testing. The results of this research prove that the high vacuum die-casting process is useful for manufacturing of aluminium components under high internal pressure.

• Journal of Korea Foundry Society
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• v.32 no.2
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• pp.65-74
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• 2012

In this paper, we present the results of our studies on optimal die design towards development of a vacuum die casting process to fabricate fuel cell bipolar plate with micro-channel array. Cavity and overflow shape is designed by computational filling analysis of MAGMA soft. Optimal die design consists of seven overflows at the end of cavity and three overflows at each side wall of cavity. The molten metal that passed the gate and reached the side wall flowed into the side overflow, no turbulent flow occurred, and the filling behavior and velocity distribution were uniform. In addition, partially solidified molten metal passing through the channel was perfectly eliminated by overflow without back-flow. When vacuum pressure, injection speed of low and high region was 300 mbar, 0.3 m/s and 2.5 m/s respectively with Silafont 36 die casting alloy, sound sample without casting defects was obtained. The experimental results are nearly consistent with simulation results.

• Journal of Korea Foundry Society
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• v.31 no.2
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• pp.71-78
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• 2011

This study aims to investigate the formability of bipolar plates for fuel cell fabricated by vacuum die casting of ALDC 6. Cavity shape of mold is thin walled plate (size: $200mm{\times}200mm{\times}0.8mm$) with a serpentine channel (active area: $50mm{\times}50mm$). Before bipolar plate was made by HPDC, computational filling behavior and solidification was performed by MAGMA soft. The final mold design for location and direction of channel was determined by computational simulation. Also, according to injection speed conditions, simulation result was compared to actual die casting experimental result. When vacuum pressure, injection speed of low and high region is 350 mbar, 0.3 m/s and 2.5 m/s respectively, products had few casting defects. On the other hand, at the same as injection speed, without vacuum pressure, products had many casting defects between end of the channel and overflow.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.11
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• pp.74-80
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• 1999

In this study, a stereolithography apparatus (SLA) prototype is used as a master model to be transformed into the silicone pattern by vacuum tool forming. The tool for the first prototype is fabricated by using this silicone pattern. Following this procedure, a temporary tool with metal powder and epoxy for wax injection is prepared for the die set of quick change type which consists of upper and lower base die나 and an insert die. The die set of quick change type appears to be very effective in casting operation by changing tools rapidly. The original wax pattern is formed through the die set, and is made of lost-was. Finally the lost-wax pattern is applied to investment casting. The final casting product is checked regarding its dimensional accuracy.

• Journal of the Korean Society of Industry Convergence
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• v.21 no.1
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• pp.1-8
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• 2018

The purpose of this study is to develop a high-strength, high-toughness, thin-walled aluminum shock absorber housing product by applying a high vacuum die casting method to improve internal gas defect and formability. The analysis program dedicated for the casting was used because it was too costly and time-consuming to adopt the gating system design. The final casting plan was designed based on the flow pattern of the material filled into the mold and the result of air pressure and air pocket after the material was completely filled in the mold. Gaty shape was designed as a split type. The runner was designed to have the same shape as the initial inlet curve of the cavity, and the flow of the molten metal was prevented from turbulent flow. The most favorable results were obtained when the injection speed was $V_2=4.0m/s$. Defects on pores were reduced by applying high vacuum level inside the mold.

• Journal of Korea Foundry Society
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• v.32 no.1
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• pp.16-23
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• 2012

In this study, we develop the lower pressure die casting with rheo-forming process of A356 aluminum alloy and vacuum system which can control the crystal size and obtain the high strengthened-light material. Using this process, we fabricate the thin plate for bipolar plate through the low pressure die casting with electromagnetic stirring and vacuum-evacuation which can control the crystal grain by electromagnetic stirring. Thin plate ($110mm{\times}130mm{\times}1mm$) is fabricated by this process. The average Vickers hardness of thin plate is about 77 HV.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.35 no.2
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• pp.196-203
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• 2012

When manufacturing die casting mold, generally, the casting layout design should be considered based on the relation between injection system, casting condition, gate system, and cooling system. Also, the extent or the location of product defects were differentiated according to the various relations of the above conditions. High-qualified products can be manufactured as those defects are controled by the proper modifications or the changes of die casting mold with the conditions. In this research, the proper manufacturing method was derived intensively for reducing the defect of the internal porosity of steering wheel housing which is very complicated to achieve a good mold design. The method was also derived for minimizing and for guaranteeing the product quality through the analysis of the casting problem and the deduction of alternative plans.

• Journal of Korea Foundry Society
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• v.31 no.5
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• pp.274-283
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• 2011

The vacuum die casting is a promising candidate of the stamping process for fabrication of fuel cell bipolar plate due to its advantages, such as precision casting, mass production and short production time. This study proposes vacuum die casting process to fabricate bipolar plates in fuel cell. Bipolar plates were fabricated under various injection conditions such as molten metal temperature and injection velocity. Also, according to injection velocity conditions, simulation results of MAGMA soft were compared to the experimental results. In case of melt temperature $650^{\circ}C$, misrun occurred. When the melt temperature was $730^{\circ}C$, mechanical properties were low due to dendrite microstructure. Injection velocity has to set at more than 2.0 m/s to fabricate the sound sample. When melt temperature, injection velocity (Fast shot), and vacuum pressure are $700^{\circ}C$, 2.5 m/s and 30 kPa respectively, sample had good formability and few casting defects. Simulation results are mostly in agreement with experimental results.