Alu-V® is AZTERLAN’s advanced forced ventilation system for aluminum die casting, engineered to create optimal vacuum conditions inside the mold and dramatically reduce defect risk in HPDC components.
The result: lower porosity, superior quality, and greater reliability, empowering the production of next-generation structural components and high-end parts with the strictest quality demands.
- Forced evacuation of trapped gases from the mold.
- Removal of residual fluids following the lubrication process
- Improved mold filling and enhanced component quality
Advantages
- Reduced porosity
- Fewer defects such as skins and cold shuts
- Improved mechanical properties
- Reduced wear
- Lower filling speeds
- Lower specific pressure enables the use of HPDC machines with reduced clamping force while achieving equivalent component performance
- Enhanced HPDC process stability
- Lower variability in key process parameters (lubrication, emissions, mold temperatures, etc.)
- Consistent and repeatable mold filling
- Shorter cycle times through reduced lubrication requirements
- Reduced second-phase injection speeds
- Full monitoring of the die casting cell, with control of the most critical process variables
- Adjustable vacuum level tailored to product and process requirements
- Self-maintenance capabilities
- Intuitive, user-friendly display suitable for different technical profiles
- Advanced monitoring of critical process parameters
- Clear and easy-to-interpret system outputs
- Fast and reliable data acquisition
- Simple programming synchronized with piston movement
- Automatic detection of leaks and contamination
- Customization to the customer’s specific process
- Feasibility assessment and system optimization for ALU-V® implementation
- Full integration into the customer’s production process
- Personnel training
- Maintenance and calibration services
- Dedicated technical support
- Product quality characterization for components manufactured with ALU-V® (CT scanning, VDS analysis, blister testing)
Sequential vacuum
1 stage
2 stages
3 stages
4 stages
Vacuum level (mbar)
<400
<200
<20
<15
Die casting machine [kN]
5.000-7.500
7.500-12.000
12.000-40.000
<120.000
Leak test
yes
yes
yes
yes
Contamination test
yes
yes
yes
yes
Full process monitoring (*)
yes
yes
yes
yes
Self-cleaning
yes
yes
yes
yes
High vacuum for structural components
no
no
yes
yes
(*) full process monitoring: vacuum pressure of the airflow synchronized with the die casting curves
The Alu-V® system offers all the vacuum pressure monitoring data synchronized with the casting curves.
This is a highly relevant information that can help detect pressure leaks in the molds and, therefore, prevent manufacturing defects due to poor mold closure.
“The Foundry of the Future is that of connected processes that is able to take advantage of the knowledge generated inside the company at the same time that it keeps learning from its manufacturing and market experience.
Along with a deep knowledge of metallurgy, Industry 4.0 technologies, advanced data management systems and machine learning technologies have landed in this industry to transform the way castings are conceived”.
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