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VACUUM FOR HIGHER QUALITYIn pressure die casting

3Company | FONDAREX

Pioneering spirit

Founded in 1946 in Switzerland, Fondarex is the inven-tor of the vacuum technology for pressure die casting and plastic injection molding. As international market leader in these two fields, Fondarex continues to invest in research and development and is committed to meeting the demands of current technology and market requirements.

The Fondarex team works to ensure its customers’ success, by guaranteeing the production of cost-effective, high quality parts with its vacuum systems. Offering customized consulting, training for users and technical support, Fondarex is your partner for the future.

CONTENT

COMPANYPIONEERING SPIRIT / HISTORY 3TECHNOLOGYOUR PRINCIPLE / RESEARCH & DEVELOPMENT 6-7OUR PERFORMANCES / YOUR ADVANTAGES 8-9PRODUCTS VACUUM SYSTEMS 12-23HUMIDITY SENSOR 20-21VACUUM VALVES 24-27CHILL-BLOCKS 28-31SERVICESVACUUM APPLICATION STUDIES 34-35TECHNICAL SUPPORT / SPARE PARTS 36TRAINING / INTERNATIONAL FORUM ON VACUUM DIE CASTING 37CONTACT 38-39

A FASCINATION FOR VACUUM

History – A rise to the top

1946 Fondarex is set up as a pressure die casting foundry by Mr. Fritz Hodler, in Montreux

1952 Invention of the first vacuum system for the pressure die casting industry

1989 Fondarex is taken over by Mr. Konrad Baumgartner

2002 Launch of the first vacuum system for the plastic injection molding industry

2010 Launch of the HIGHVAC ECONOMY 1C, PROGRESS 2C and PREMIUM 2C vacuum systems

2012 Launch of the HIGHVAC ULTIMATE 4C vacuum system and the HIGHVAC EXVAC shot sleeve air evacuation system

2016 Launch of the HUMIDITY SENSOR, the advanced vacuum unit and the pump management system

6 7Technology | FONDAREXFONDAREX | Technology

HIGHVAC ULTIMATE 4C 2000

HIGHVAC PREMIUM 2C500

Our principle

In pressure die casting, since filling a cavity with an alloy is extremly rapid, vacuum technology is recognized as being the most efficient solution to evacuate air and gas. With this technology, superior quality parts can be produced. Today, vacuum technology plays a key role in the production of complex and high quality parts such as structural parts.

In its innovative vacuum technology, Fondarex uses two methods of guaranteeing optimum evacuation un-til the end of the filling phase: patented mechanical valves that close in 1 millisecond or chill-blocks with an ingenious aerodynamic profile.

The Fondarex vacuum system is suitable for all pro-duction cells and molds. It is the technology peripheral device for pressure die casting (Al, Mg, Zn) providing additional injection process control.

Research & Development

Fondarex’s research and development engineers con-tinually strive to perfect the vacuum process in die cast-ing and plastic injection molding.

They work in close collaboration with universities, techni-cal centers and customer partners throughout the world. Today, Fondarex counts more than 1000 customers in over 50 countries. With this perfect synergy between market and research, Fondarex continues to develop its technology to meet its customers’ in crea sing demands. Indeed, this is certainly one of the main reasons behind Fondarex’s position as world market leader.

VACUUM:THE EVACUATION GENIUS

A StandardB Optional

BA

mbar

1000

1500

500

100

t

8 9

VACUUM MAKESTHE DIFFERENCE

Curves Standard evacuation (no vacuum) Standard vacuum Regulated vacuum example A Regulated vacuum example B

Technology | FONDAREXFONDAREX | Technology

The specialist

Fondarex, the leading specialist in vacuum systems can help you achieve the most difficult projects, such as auto motive structural parts, heat treated parts, thin-walled parts, surface parts and safety parts.

Your advantages

- Increased density of die cast parts - Improvement of surface quality (ideal for future surface treatments)

- Significantly less porosity - Perfect filling of complex molds - Allows temperature treatments (T4, T5, T6, T7) - Required for welded parts - More cost-effective and sustainable production thanks to reduced reject rates

Fondarex vacuum systems immediately guarantee stable, efficient and cost-effective production.

Fondarex efficiency curves

Evolution of the air pressure in the mold cavity during the injection process.

MULTIFACETED PERFORMANCE

Our performances

1 Consulting and expertise - Integration of the vacuum system in your production cells

- Overall view of the casting process (mold design, injection parameters, shot sleeve / plunger system and spraying / thermo regulation system)

2 Vacuum application studies - Mold adaptation and design, in particular the gating system and vacuum channels

- Injection parameter recommendations

3 Products - HIGHVAC, a modular vacuum system that can be tailo red to meet customers’ needs, compatible with all die casting machines and all molds; multilingual control panel and user manual; optional HUMIDITY SENSOR, advanced vacuum unit and HIGHVAC EXVAC

- SUPERVAC vacuum valves and CHILL-BLOCK venti-lation plates

- Products 100% made in Switzerland

4 Customization - Fully customized vacuum system tailored to meet customer needs

- Smart options to optimize the control of the injection / vacuum process

5 Training - Regular vacuum technology training sessions at Fondarex or on-site: application studies, operation and maintenance of vacuum systems

6 Technical support - Quick and efficient worldwide service - Installation of vacuum systems on the production site and user training

- Production site troubleshooting and maintenance

7 Spare parts - Spare parts are shipped within 24 hours

8 Research & Development - Our team of engineers continually strives to perfect the vacuum process for pressure die casting.

- Close collaboration with universities, technology centers as well as customer partners throughout the world

1

Customer

8 2

7 3

6 4

5

13

REINFORCEMENTS FOR PRESSURE DIE CASTING MACHINES

Products | FONDAREX

14 15

HIGHVAC ECONOMY 1C

HIGHVAC PROGRESS 2C

HIGHVAC ECONOMY 1C250

HIGHVAC PROGRESS 2C500

HIGHVAC ECONOMY 1C 1000

HIGHVAC ECONOMY 1C CENTRAL



HIGHVAC PROGRESS 2CCENTRAL



The essential from Fondarex, in its most modular form.

Easy to use, ideal for all applications. Two independent vacu um channels for optimum flexibility.

Fondarex’s eco-nomic vacuum system.

One vacuum channel, ideal for basic appli-cations.

FONDAREX | Products Products | FONDAREX

16 17







HIGHVAC PREMIUM 2CCENTRAL

HIGHVAC PREMIUM 2C

HIGHVAC ULTIMATE 4C




HIGHVAC ULTIMATE 4CCENTRAL

HIGHVAC EXVAC

The accessory for evacu-ating air from the shot sleeve. Suitable for all machines thanks to its ultra-compact design. A single vacuum channel with vacuum regulation and pollution control.

The ultimate solu tion from Fondarex:The most power-ful and ingenious vacuum system.

Fondarex perfec-tion with a fully controlled vacuum process.

Optimum for complex applications such as structural parts that require the highest per-formance. Two independent vacuum channels with vacuum regulation and an eva-cuated air volume measurement. Total process control and easy data transfer with the Ethernet pack or the USB flash drive.

The best for structural parts. Four independent vacuum channels for the most extreme applications requiring a near absolute vacuum. Total process control and easy data transfer with the Ethernet pack or the USB flash drive.


8

18 19

THE TOTAL SOLUTION FORSTRUCTURAL PARTS


1 Pump management system2 Vacuum tank 3000 l3 Vacuum pumps 3 x 160 m3/h4 Control panel5 HIGHVAC ULTIMATE 4C 6 HUMIDITY SENSOR 7 HIGHVAC EXVAC8 Advanced vacuum unit 9 SUPERVAC MACRO vacuum valve

1

2

34

9

7

5

6

We integrated our very best tech-nologies to give you the ultimate process control.

20 21

HUMIDITY SENSOR

Curves Humidity measurement channel A Humidity measurement channel B Tolerance threshold Selected area Out of tolerance signal

50

40

30

20

10

0 (ms)

0 200 400 800600 1000

HUMIDITY SENSOR

HIGHVAC PREMIUM 2C500 WITH HUMIDITY SENSOR


The world’s first look at air evacuation

Fondarex has developed an optical sensor capable of precisely determining the humidity content of air evacuated from the cavity. Fast, accurate and reliable, it measures and processes production data for each vacuum channel and each shot.

This is the most innovative analytical equipment for vacuum die casting.

Primary characteristics: - Humidity measurement via a specially developed optical sensor

- Automatic data processing using an independent processor

- Limits threshold setting for process quality control - Sensor self-cleaning and calibration after each shot for enhanced reliability and low maintenance

- Compatible exclusively with models HIGHVAC PREMIUM 2C and HIGHVAC ULTIMATE 4C

Patented worldwide

22 23

Technical data: HIGHVAC vacuum systems

HIGHVACECONOMY 1C 250

HIGHVAC ECONOMY 1C 1000

HIGHVAC ECONOMY 1C CENTRAL

HIGHVAC PROGRESS 2C 200





HIGHVAC PROGRESS 2C CENTRAL

HIGHVAC PREMIUM 2C 200






HIGHVAC PREMIUM 2C CENTRAL




HIGHVAC ULTIMATE 4C CENTRAL

HIGHVACEXVAC

Die casting machine tonnage (t) < 600 approx. < 3000 approx. all < 600 approx. < 2000 approx. < 3000 approx. < 3000 approx. < 4500 approx. all < 600 approx. < 2000 approx. < 3000 approx. < 3000 approx. < 4500 approx. < 4500 approx. all < 3000 approx. < 4500 approx. < 4500 approx. all all

VACUUM SYSTEM FRAME

Mobile unit (on wheels) - - - - - - - - - - - - - -

Frame and tank material Stainless steel

Stainless steel

Stainless steel

Stainless steel

Stainless steel

Stainless steel

Stainless steel

Stainless steel

Stainless steel

Stainless steel

Stainless steel

Stainless steel

Stainless steel

Stainless steel

Stainless steel

Stainless steel

Stainless steel

Stainless steel

Stainless steel

Stainless steel

Stainless steel

Vacuum tank capacity (l) 250 1000 - 200 500 800 1000 2000 - 200 500 800 1000 2000 3000 - 1000 2000 3000 - -

Vacuum value in the tank (mbar) 1 1 - 1 1 1 1 1 - 1 1 1 1 1 1 - 1 1 1 - -

External dimensions (mm) Width Depth Height

7007001350

25509001450

600210600

8009001520

80012901520

80012902150

25509001450

300011001800

800300600

8009001520

80012901520

80012902150

25509001450

300011001800

315012002020

800300600

25509001450

300011001800

315012002020

1470400720

490210680

Weight (kg) 260 490 50 295 337 385 520 690 80 298 338 386 521 691 1030 81 598 768 1107 158 31

VACUUM SYSTEM COMPONENTS

Vacuum pump BUSCH Series RA (m3/h) 1 x 25 1 x 100 - 1 x 25 1 x 40 1 x 63 1 x 100 1 x 160 - 1 x 25 1 x 40 1 x 63 1 x 100 1 x 160 1 x 160 - 1 x 100 1 x 160 1 x 160 - -

Automation SIEMENS HMI PLC

TP 700 - 7"S7-1214

TP 700 - 7"S7-1214

TP 700 - 7"S7-1214

TP 700 - 7"S7-1214

TP 700 - 7"S7-1214

TP 700 - 7"S7-1214

TP 700 - 7"S7-1214

TP 700 - 7"S7-1214

TP 700 - 7"S7-1214

TP 900 - 9"S7 1500

TP 900 - 9"S7 1500

TP 900 - 9"S7 1500

TP 900 - 9"S7 1500

TP 900 - 9"S7 1500

TP 900 - 9"S7 1500

TP 900 - 9"S7 1500

TP 1200 - 12"CPU 315-2

TP 1200 - 12"CPU 315-2

TP 1200 - 12"CPU 315-2

TP 1200 - 12"CPU 315-2

TP 177 - 4"

S7-1214

Pneumatic system FESTO

Number of vacuum channels 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 4 4 4 4 1

Evacuation section of vacuum channels (mm2) 1 x 500 1 x 500 1 x 500 2 x 500 2 x 500 2 x 500 2 x 500 2 x 500 2 x 500 2 x 800 2 x 800 2 x 800 2 x 800 2 x 800 2 x 800 2 x 800 4 x 800 4 x 800 4 x 800 4 x 800 1 x 500

Vacuum regulation system - - - - - - - - -

Buffer tank - - - 1 x 5 l at 6 bar 1 x 5 l at 6 bar 1 x 5 l at 6 bar 1 x 5 l at 6 bar 1 x 5 l at 6 bar 1 x 5 l at 6 bar 1 x 5 l at 6 bar 1 x 5 l at 6 bar 1 x 5 l at 6 bar 1 x 5 l at 6 bar 1 x 5 l at 6 bar 1 x 5 l at 6 bar 1 x 5 l at 6 bar2 x 5 l at 6 bar1 x 5 l System

pressure

2 x 5 l at 6 bar1 x 5 l System

pressure


pressure


pressure-

Language pack (English, German, French, Italian, Spanish, Portuguese, Swedish, Turkish, Polish, Czech, Romanian, Russian, Chinese, Japanese, Korean)

VACUUM SYSTEM MONITORING AND MEASUREMENTS

Vacuum measurements and monitoring per vacuum channel

Illustration of the vacuum curve per vacuum channel -

Export and storage of vacuum curves on USB (Excel) - - - - - - - - - -

Pollution control per vacuum channel

Illustration of the pollution control curve per vacuum channel - - - - - - - - - - - - - -

Profile control per vacuum channel -

Illustration of the profile control curve per vacuum channel - - - - - - - - - - - - - -

Evacuated air volume measurement per shot - - - - - - - - - -

Leak test (mold and shot sleeve) - - - - - - - - - -

Settings: Internal storage of settings for individual projects/molds (no. of files) / External backup/restore of settings (Excel) via MMC/USB

50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 -

Log data: Internal storage of production data (no. of cycles) / External backup of production data (Excel) via MMC/USB/Ethernet

200 200 200 200 200 200 200 200 200 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 -

Control of all types of Fondarex SUPERVAC valves and CHILL-BLOCKS -

Control of all valves types (other brands) - - - - - - - - - -

Standby mode -

Calibration of vacuum sensors - - - - - - - - - -

Alarm management (process and maintenance) - - - - - - - - - -

Error diagnostics display

Recording of error log data - - - - - - - - - -

Interface: Potential free contacts

VACUUM SYSTEM OPTIONS

Pump upgrade (m3/h) 1 x 40 2 x 100 - 1 x 40 1 x 63 / 1 x 100 1 x 100 2 x 100 2 x 160 - 1 x 40 1 x 63 / 1 x 100 1 x 100 2 x 100 2 x 160 2/3 x 160 - 2 x 100 2 x 160 2/3 x 160 - -

Ethernet Pack -

PROFINET and/or PROFIBUS interface - - - - - - - - -

HUMIDITY SENSOR - - - - - - - - - -

Advanced vacuum unit - - - - - - - - - - - - - - - - -

SWISS MADE


(subject to change)

25

THE ORIGINALIS BEST

Products | FONDAREX

26 27

SUPERVAC MAXI SUPERVAC MACRO

VACUUM VALVESMONOVAC / SUPERVAC

SUPERVAC MINI SUPERVAC MEDIO

Patented worldwide

MONOVAC

MONOVAC 1 piston valve

Evacuation during the first injection phase. Compression spring closure, controlled by a signal from the die casting machine.

SUPERVAC Ingenuity from Fondarex: The most powerful valve in the world.

Maximum evacuation until the mold is com-pletely filled. Ultra-fast valve closure in one millisecond, using the metal’s kinetic energy.

Technical data: MONOVAC / SUPERVAC vacuum valves

MONOVAC SUPERVAC MINI SUPERVAC MEDIO SUPERVAC MAXI SUPERVAC MACRO

Die casting machine tonnage (t)

400 – 3000 < 400 approx. 200 – 1200 800 – 2800 1600 – 4500

CHARACTERISTICS

Closing system Controlled closure(by compression spring)

Closed by the kinetic energy of the metal




Closing time (ms) 100 1 1 1 1

SCOPE

Al / Mg

Zn - - -

Shot weight Al (kg) 4 – 25 0,3 – 1,5 1 – 12 6 – 25 12 – 45

Shot weight Mg (kg) 3 – 17 0,07 – 1 0,7 – 8 4 – 16 8 – 30

Shot weight Zn (kg) - 0,2 – 4 3 – 20 - -

TECHNICAL DATA

Valve Compensator Valve Compensator Valve Compensator Valve Compensator Valve Compensator

Width (mm) 130 130 63 63 100 100 140 140 150 150

Depth (mm) 100 80 63,4 63,5 88,9 88,9 108 108 139,7 139,7

Height (mm) 134 134 76 75 127 126 152 151 171 170

Weight (kg) 13 10,8 3 2,3 9,6 8,4 19 16,4 28,4 25,4

(subject to change)

SWISS MADE


29

THE TALENT OFAERODYNAMICS

Products | FONDAREX

30 31

CHILL-BLOCKS SCCZ / SCS

SCS 100SCS 30 SCS 60SCCZ 12

CHILL-BLOCKS

Efficient evacuation until the die is completely filled. Solidification of metal in the aerody-namic profile.

SCCZ (Steel Chill Compact Zinc)SCS (Steel Chill Standard)

SCS 60 / 100 / 140

Also available with water cooling. CHILL-BLOCK SCCZ 12 CHILL-BLOCK SCS 30 CHILL-BLOCK SCS 60 CHILL-BLOCK SCS 100 CHILL-BLOCK SCS 140

Die casting machine tonnage (t)

< 200 approx. < 400 approx. 200 – 1200 800 – 2800 1600 – 4500

CHARACTERISTICS

Closing system Solidification of metal in the profile

Solidification of metal in the profile




SCOPE

Al / Mg -

Zn - -

Shot weight Al (kg) - 0,1 – 1,5 0,7 – 10 5 – 22 10 – 40

Shot weight Mg (kg) 0,05 – 0,8 0,07 – 1 0,5 – 6 3 – 12 6 – 26

Shot weight Zn (kg) 0,1 – 3 0,2 – 4 1 – 20 - -

TECHNICAL DATA

Fixed part Mobile part Fixed part Mobile part Fixed part Mobile part Fixed part Mobile part Fixed part Mobile part

Width (mm) 63 63 63 63 100 100 140 140 150 150

Depth (mm) 63,4 63,5 50 50 50 50 60 60 80 80

Height (mm) 100 99 150 149 250 249 300 299 360 359

Weight (kg) 2,9 2,8 4,1 3,9 9,4 8,5 18,8 17,2 30,6 32,6

Technical data: CHILL-BLOCKS SCCZ / SCS SWISS MADE

(subject to change)


SCS 140

2

3

1

5

6

4

HIGH-LEVEL PRESSURE DIE CASTING

1 Half cylinder block (Boxer 2-cylinder motorcycle) / BMW AG2 Hydraulic control unit for gearbox / METALLWERK FRIEDRICH DEUTSCH GmbH for MERCEDES-BENZ AG3 Cylinder block (4-cylinder motor block automobil) / BMW AG4 Shock tower / ALBERT HANDTMANN METALLGUSSWERK GmbH & Co.KG for BMW AG5 Door handle locking armature truck / SCHLIEPER Ges.m.b.H for VOLVO TRUCK CORPORATION6 Car body element / DGS DRUCKGUSS SYSTEME AG for AUDI AG

34 35

OUREXPERTISE

Vacuum application studies

Fondarex, specialist in vacuum application studies: - Determines the evacuation system - Sizes and adapts the gating system - Sizes and adapts vacuum channels - Offers advice on injection parameters

A team of experts provides support to help you in the most challenging situations.

FONDAREX | Services Services | FONDAREX

Consulting and expertise

With more than 60 years experience in vacuum tech-nology, Fondarex has acquired extensive know-how that it is committed to sharing with its customers.

Through specific consulting services and responsive support, the technical team provides the expertise required to ensure our customers’ success.

36 37

AT YOURSERVICE

LESS AIR MORE KNOW-HOW

Technical support

Our team of engineers provides quick and efficient service on production sites across the world. Through its strong international presence, Fondarex maintains a close relationship with its customers.

Fondarex offers a full maintenance contract that in-cludes the regular maintenance of vacuum systems on production sites, software upgrades, ongoing training for personnel and special conditions for spare parts. The full maintenance contract ensures you achieve maximum productivity from your vacuum system: A competitive advantage.

Spare parts

Each day, the Fondarex vacuum system delivers optimum performance. Fondarex original spare parts are made in Switzerland to guarantee the smooth operation and longevity of our products. Fondarex ships spare parts with in 24 hours. Spare parts are available locally in Switzerland, Germany, United States and China.

Training

Fondarex regularly organizes training sessions on vacu-um technology, vacuum applications and how to use and maintain vacuum systems.

Training sessions can be tailored to meet the interests and needs of participants, whether they are operators, service staff, engineers or managers. Training can be given on site or at our premises.

International Forumon Vacuum Die Casting

Fondarex is dedicated to bringing together the main players from the pressure die casting industry: Found-rymen and metallurgists, machine and peripheral device manufacturers, die makers and scientists, as well as all other specialists involved in the field.

Every three years, Fondarex organizes the International Forum on Vacuum Die Casting, in Montreux. Profes-sionals from the industry present the latest innovations and debate on current topics and the future.

FONDAREX | Services Services | FONDAREX

38 FONDAREX | Services

FONDAREX SARoute Industrielle 131806 St-LégierSwitzerland

T + 41 21 943 000 0F + 41 21 943 000 1info @fondarex.comwww.fondarex.com

EUROPE

BULGARIACZECH REP.ENGLAND GERMANYGREECEITALYPOLANDPORTUGALROMANIASPAINSWEDENSWITZERLAND TURKEY

ASIA

CHINAINDIAJAPANREP. OF KOREA

AMERICA

ARGENTINA BRAZILUNITED STATES

Our worldwide representations:

First edition 2013 Second, expanded edition 2016

COPYRIGHT © 2016 FONDAREX SA

www.fondarex.com

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