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Vacuum casting draws molten metal into a mold, reducing turbulence and preventing impurities. It is cost-effective and efficient, with a higher quality final product. Vacuum sand casting and elastomer casting are also used with similar benefits.
Vacuum casting is one of the three main casting methods that can be used to draw materials into molds. A number of benefits can be associated with vacuum casting, many of which make it suitable for working with both ferrous and non-ferrous metals. The process typically involves drawing molten metal into a mold, which can result in less turbulence and prevent slag and other impurities from entering the final casting. Vacuum casting is often associated with a common variant of sand casting and can also be used with elastomers.
Another name for vacuum casting is back-gravity filling, as it typically involves pulling a material into a mold rather than pouring it from above. Because the material is not poured or forced using air pressure, there is typically little turbulence associated with this method. This can allow injection mechanisms to be less complex than with other types of casting, which can reduce overall costs.
The simplicity of the gating mechanism can also improve the efficiency of the method, as less metal tends to solidify on it. This can result in an increase in efficiency of 50% or more. The final quality of the part can also be higher, as less turbulence can result in free floating slag in the upper part of the vessel. As the molten material is drawn from below the surface of the pool, the slag is typically left behind.
Vacuum sand casting is a variation that uses a vacuum to form sand in a plastic mold and is often used with various types of metal. A thin piece of plastic is typically placed over the mold, then sand is drawn over it with a vacuum. The sand contacts the plastic sheath rather than the mold itself, but takes the shape of the mold. The molten metal can then be drawn into contact with the sand, at which point it will take the shape of the mold. When the vacuum is removed, the sand will release the solidified metal and the mold can be used again.
Vacuum casting is also used for elastomers if other methods cause air entrapment problems. This method typically uses a silicone mold that is placed inside a vacuum chamber. A liquid elastomer will then be degassed before being introduced into the mould. The vacuum can help ensure that the elastomer fills all detailed parts of the mold as well as reduce the possibility of air bubbles. After the mold has filled, the vacuum can be removed and the part can be further machined.
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