Pressure over Vacuum Casting Machines

TVCd-XL is a family of bottom pouring induction vacuum casting machines designed to meet the more severe needs in lost wax casting of ferrous and nonferrous alloys.
They are often used in connection to a 3d printer for direct casting to get metal parts of complex objects.

In TVCd-XL, melting of the metal takes place in a protective atmosphere (nitrogen, argon or forming gas) and a powerful vacuum pump is supplied to obtain the maximum suction effect in the mould chamber.

The consumption of the graphite crucible is greatly reduced thanks to the gas washing process, which removes the oxygen within seconds of the charge being loaded. The heating system consists of a medium frequency induction generator, while the temperature is measured by a thermocouple with an accuracy of 1%.

In addition, once the metal has entered the mould, compression is applied during solidification to reduce shrinkage porosity.

Moreover, the operator can decide to load the flask in the flask chamber when the alloy is already melted, just few minutes before casting.
This leads to a low temperature drop in the flask and avoid excessive flask overheating to compensate this risk.

In case of challenging castings, this machine can also work with a new, revolutionary double chamber concept. In this working mode, melting chamber and flask chamber are completely independent and, at the moment of casting, the machine can control the metal injection into the flask by applying a differential pressure during pouring.

This yields to a faster injection compared to the simple gravity pouring with the benefit to cast items at lower temperature. This will result in smaller grain sizes and better surface finishing of the cast parts.

The machine is fully automatic having more than 100 programs for every kind of alloy.

Technology & Features

Gas Wash Procedure

• Crucible loading operation introduces oxygen
• The Gas Wash Purge procedure removes the oxygen in a very fast and efficient way and then refills back the chambers with Argon, Nitrogen or Forming Gas 
• Compared with the traditional crucible protection with flow-meter regulation, gas consumption is dramatically reduced, alloys oxidation is minimized and crucible life is greatly increased.
• Moreover the crucible life is increased: TVC series crucible last up to 250 – 400 casting cycles according to the graphite quality

Melting

• Advanced Self Tuning thermoregulation (AST™) with accurate temperature control of the melted alloys
• Two Set-Points available: Homogenization and Casting Temperature
• Medium frequency induction heating stirs the melted alloy and leads to a very high homogeneity
• Pulse Stirring Management (PSM™) for an extremely low frequency stirring
• Highest power density in the market features strong stirring

Casting

• Bottom Pouring casting when the stopper lifts-up
• Possibility of setting the vacuum level at the moment of casting
• Flask Chamber provided with Pneumatic Piston for easy shell loading and unloading

Tree protection after casting

• Thanks to the double chamber concept, after the solidification phase, the flask cools down in a protective atmosphere while at the same time you can load your alloy in the melting chamber for the next melting. This operation will allow an overlapping of the casting cycles which will give you the ability to protect longer the tree before removing it without losing time and productivity.

Technical data

(Customized models are available on request with special features)

	TVC25d	TVC35d	TVC45d
Crucible volume	2 or 3 liter	4 liter	7 liter
Crucible working capacity	10 kg Steel (*) 3 kg Magnesium 5 kg Aluminium 18 kg Bronze	15 kg Steel (*) 4.5 kg Magnesium 7 kg Aluminium 24 kg Bronze	20 kg Steel (*) 8 kg Magnesium 13 kg Aluminium 42 kg Bronze
Flask maximum diameter (mm)	350   /    450
Flask maximum height (mm)	600	600	600
Induction power	25 kW	35 kW	45 kW
Vacuum pump	Internal	Internal	Internal
Pressure over vacuum	1 bar	1 bar	1 bar
Max. temperature	1250 °C   /   1600 °C
Temperature control	2 thermocouples
Metal granulation
Industry 4.0
Autotest
Monitoring system for data acquisition
Flask check before casting
Vacuum leakage detector
Oxygen Analyzer
Remote assistance
Main alloys	Gold (Au), Silver (Ag), Copper (Cu), Brass, Bronze, Steel, Aluminium (Al) and their alloys; Magnesium alloys require a special option, available on request.

 

 Provided -  Available on request - (*) Version TVCd-FNF for ferrous and non-ferrous metals - crucible volume may vary