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CONTECH’s Thintech High Vacuum process is a variant of the enhanced HPDC process that is capable of producing high integrity, thin walled components that are both heat treatable and weldable.
Castings produced by the Thintech process are suitable for structural applications as well as for Chassis and Suspension systems. In this unique process, a high level of vacuum is achieved in the die cavity and shot chamber prior to the injection of metal. Advanced vacuum monitoring techniques are utilized to ensure proper functioning of the vacuum system. This high level of vacuum coupled with a rigorous metal handling process results in Thintech components that exhibit very low levels of entrapped gas. This low gas level allows subsequent processing that until now was not compatible with high pressure die castings. The integrity of the castings, further enhanced by heat treating, result in high performance components for a variety of applications.
Targeted Overall Wall Thickness: 2mm – 4mm
Product Focus
• Suspension Components
• Chassis Components
• Body Structure Components
Alloy
• Aural 2
Physical Properties
• Elevated Tensile Properties
• Tight Dimensional Control
• Minimal Porosity
• Refined Microstructure (Rapid Solidification)
Benefits
• Minimal Distortion
• Corrosion Resistance
• Can be Joined to other Non-Ferrous or Ferrous Materials (Riveting, etc.)
• Improved NVH (Noise, Vibration, Harshness)
Design Advantages
• High Ductility / Crash Performance
• Weldability /Joinability
• Complex Geometries
• Replaces Multiple-Part Assemblies
Overall Advantages
A combination of advanced simulation techniques, proprietary alloys, metal handling systems, tooling designs, gating, vacuum systems, process controls, and heat treatment systems culminate in a process that produces castings that exhibit superior mechanical properties. Thin-Tec products are uniquely positioned to replace steel stamping assemblies in a variety of applications.
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Process Attributes
• Horizontal shot and vertical die clamping
• Multiple cavities
• Premium grade H13 for cavities and cores
• Sealed dies
• Use of vacuum (>29” Hg)
• Utilizes advanced vacuum monitoring equipment
• Preferred wall thickness ~ 2-5 mm
• Heat treatable (T4, T5, T6 & T7)
• Commonly used alloys – Aural2 and Aural3
• Can be joined by welding and/or riveting
• High strength and/or high ductility
• Low susceptibility to shrink porosity/oxides
• Metal cleanliness >97% density index |
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