VACURAL® - a new dimension in quality
The VACURAL die-cast process facilitates the cost-effective and environmentally-friendly production of lightweight parts and components to an unprecedented level of quality. We partnered with VAW and Müller-Weingarten to develop the VACURAL process and ultimately to get it to the stage where it was ready for full-scale production. Today VACURAL is one of the most process-reliable special die-casting processes available.

Aluminum die-casting manu- factured using the VACURAL® process are 
• formable
• heat-treatable
• weldable

With conventional die-casting processes, it is impossible to avoid inclusions of vapours, gases and air in die-cast parts. These defects reduce the strength, inhibit heat treatment and often prevent the effective welding of the parts affected. Inclusion gases are highly compressed and expand during heat treatment and welding, thereby forming bubbles and cavities, which adversely affect the mechanical properties of the parts. The VACURAL process prevents this from happening by evacuating the entire casting system. Thus the VACURAL process offers significant advantages over conventional vacuum-aided die-casting procedures:
  • only pure, degassed metal is extracted from below the bath surface so that fewer oxides are introduced into the casting chamber
  • lower oxidation of the melt during the casting process
  • the defined vacuum impedes the inclusion of gases or air in the castings
  • faster solidification, which means that the aluminum alloy has a finer structural formation
High quality lightweight parts and components - with VACURAL®  
  • High structural strength and rigidity
  • Improved elongation and deformation properties
  • Die-castings can be heat-treated and formed
  • Structural parts can be accurately cast to specification, so that little subsequent machining is required. In many cases machining may be dispensed with completely
  • More cost-effective and environmentally-friendly production

With strength values of up to 360 N/mm2 and elongation values of up to 16% and more - depending on the alloy used - the VACURAL process enables mass production of safety parts to exact specifications, with extremely thin walls and excellent structural formation.
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The diagram above gives a simplified yet clear indication of the broad range of applications of VACURAL compared to other forming processes. Wall thicknesses of up to 9 mm can be achieved. 

With the VACURAL process it is possible to produce castings that enable users to achieve their cost savings objectives and have lightweight parts with the twin benefits of high static and dynamic strength and plastic deformation properties –  a development which only a few years ago seemed totally inconceivable for die-cast parts.

 

 


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