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Allround Casting Machines | VTC-Series

or every metal or alloy you want to cast

VTC Vacuum/Casting Machines

The VTC 100 V – VTC 800 V are extremely versatile casting machines suitable for a wide range of applications – and a number of options that were considered mutually incompatible up to now. Thus, while the VTC series was originally designed as a high-temperature casting machine for casting steel, palladium, platinum etc. (max. 2,000° C), large flasks also make it suitable for economically producing castings in gold, silver, copper, aluminium and other materials.

The machine combines a dual-chamber differential pressure system with a tilting mechanism. The casting process is achieved by rotating the entire melting-casting unit by 90°. One benefit of the tilting system is the use of economically priced graphite or ceramic crucibles (without holes and sealing rods), these tend to have a longer service life. Some alloys, such as copper beryllium, quickly cause crucibles with holes and sealing rods to become untight and therefore useless, and for this reason, many casters have so far processed such alloys only in open systems – which means they can’t choose to optimise the process with overpressure or vacuum.

With the VTC series, these handicaps no longer apply. A vacuum can be produced in the melting chamber and the casting chamber to avoid oxidation processes during melting and air pockets in the casting mould. The flask is automatically pressed against the melting chamber for casting, this makes it possible to switch to overpressure during casting for better mould filling; in addition, the vibration technology optimises the process even further. As well as casting with flasks, casting into ingot moulds is also possible.

New sweep mode vibration system for perfect results even in Pt and Pd

Due to the vibration technology (see page 26) and the sophisticated vacuum/pressure system, this machine is perfectly suited to casting platinum and palladium – and all without an elaborate and sensitive centrifugal mechanism. The VTC machines are equipped with the advanced sweep mode vibration system. It considers that each casting tree and even each item of a tree has a different resonance frequency, depending on its shape and size. Generating variable frequencies the sweep mode vibration ensures that the optimum frequency is covered.

New generator system controlled via LCD display

A completely new generation of generator and control systems is present in the VTC series. Operation is simple and safe thanks to a clearly arranged and easy-to-use LCD display. All parameters, right down to the variable tilting speed, can be individually set and saved to ensure that recurring castings always produce consistent results.

Data Overview of VTC-Series

■ standard equipment, ○ optional, - not available
VTC-Series VTC-Series VTC-Series VTC-Series
Power
Temperature max. 2100° C 2100° C 2100° C 2100° C
Power max. / electrical connection 12 kW (3x400v) 15 kW (3x400v) 20 kW (3x400v) 20 kW (3x400v)
Capacity
Volume ceramic crucible 30 ccm = 600 g Pt / 250 g steel 180 ccm = 2,5 kg Pt / 1 kg steel 300 ccm = 2.0 kg steel 600 ccm = 4.0 kg steel
For use of molds standard equipment 125 mm / 220 mm h, ○ 125 mm / 350 mm h standard equipment 125 mm / 220 mm h, ○ 125 mm / 350 mm h standard equipment 125 mm / 220 mm h, ○ 125 mm / 350 mm h standard equipment 125 mm / 220 mm h, ○ 125 mm / 350 mm h
Volume graphite crucible 25 ccm = 450 g Au 18 ct 145 ccm = 2,0 kg Au 18 ct 300 ccm = 2.5 kg Cu 600 ccm = 4.0 kg Cu
Operation and Control
Automatic tilting with motor drive standard equipment standard equipment standard equipment standard equipment
Vibration technology standard equipment Sweep Mode standard equipment Sweep Mode standard equipment Sweep Mode standard equipment Sweep Mode
Automatic mold fixing standard equipment standard equipment standard equipment standard equipment
Programs 100 100 100 100
Temp. measurement by thermocouple up to 1.300° C up to 1.300° C up to 1.300° C up to 1.300° C
Temperature measurement equipped with an optical pyrometer up to 2000° C up to 2000° C up to 2000° C up to 2000° C
Quality Assurance
RS 232, Ethernet, USB interface, diagnostic system ■ ■ ■ ■
Data printer ■ ■ ■ ■
GSM-modem for remote service ■ ■ ■ ■
DMS
■ ■ ■ ■
InduthermCloud ○ ○ ○ ○
iThermControl ○ ○ ○ ○
Accesories
Vacuum investment mixer Indumix 4+ ○ ○ ○ ○
Furnace AK 135 ○ ○ ○ ○
Vacuum pump ○ ○ ○ ○
Water chiller ○ ○ ○ ○
Pyrometer with video output ○ ○ ○ ○
All machine descriptions and technical data published on this site make no claim to be complete. They are subject to change and therefore they are not basis of contract.

Other Advantages of VTC-Series

Approximate duration of process: 5 min.

The DDP system is ensuring a constant and controllable metal mass flow, and therewith gas-to-metal ratio, independent from the melt level in the crucible.

The bar casting kit is developed for casting defined quantities of your alloy into ingot molds or into any other molds. The program control recognizes the applicated equipment and provides the suited parameter settings on the display.

Longer consumable life can be achieved by reducing frequent temperature changes and exposure to oxygen as much as possible. For this reason, we offer filling devices for numerous system models that enable recharging without loss of temperature and without contact with oxygen.

Very sharp separation. Wide classifying range, e.g. separation of steel or bronze from ~4 to ~120 kg/h bronze/stell (depending on version, separation at 10 µm), adjustable by the material feed.

With the sintering unit processes can take place under a vacuum, which is important for alloys with a manganese component.

Footprint of just a few square meters including infrastructure

Our self-developed generators and induction heating systems tailored to the intended use ensure maximum energy efficiency. They not only reduce power consumption, but also increase the heating speed and the maximum temperature. They also reduce electromagnetic emissions with regard to the EMC directive. Efficient encapsulation ensures that the induction generated is used with as little loss as possible for rapid melting of the metal. The thermal insulation around the inductor and crucible protects against heat radiation. This high use of energy also reduces the energy consumption for water recooling in the machine and for any air conditioning that may be necessary in the foundry.

The user-oriented and modular structure of the systems ensures optimum accessibility for all work as well as for inspection and maintenance. This construction principle also ensures short installation and training periods.

Polished stainless steel surfaces prevent powder adhesions in spray chamber, cyclone and collector – all parts are easy to clean without any residues.

Excellent mould filling thanks to high overpressure and vibration system.

Reliable production of metal powder with narrow particle size distribution and high process yield Ideal for small to medium amounts

Short training period, easy and reliable handling. Optimum accessibility for inspection and maintenance, low cleaning effort. Minimum metal loss and cross-contamination. High process stability.

Program control system for fast and certified casting processes. Thanks to the control panel with full text LCD display, all programs and parameters are very easy and convenient to set. The semi-automatic machines offer temperature programs. The fully automatic machines have a program control system involving all parameters. Up to 100 casting programs guarantee fast operation and consistent casting results. Parameters are pre-programmed for all major alloys, e.g. for AGS, Alpha Plus, Heraeus, Legor and Pandora alloys. In practice this means: from the first mold, you can expect good casting results without carrying out expensive pre-tests. The program control and the integrated data printer ensure a high level of safety and the possibility of precise process documentation (important for certified casting processes).

Möglichkeit der Oxidations-Vermeidung in der geschlossenen Anlage durch Entgasung und durch gezielte Schutzgasführung

Increase of powder quality by gas flow optimisation in the spray chamber (avoidance of satellites)

All Indutherm VC machines have separate lock systems for the melting chamber and mold chamber. This allows time to be saved by “overlapping” casting: while the mold remains in the vaccuum chamber for several minutes after the casting, you may fill in and heat up the next charge.

The AU machines offer the possibility of oxidation-free processing in the closed-chamber machine by means of de-gassing, vacuum and protective gas features.

Processes can take place under inert gas.

Depending on the thickness of the rings, up to 6 rings or bangles can be processed simultaneously.

without any satellites for the highest powder fluidity and bulk density. Could be basically used as well for non-metallic materials (certain fluidity required).

due to precise control of the melting temperature via a crucible based induction heating system, while evaporation of alloy ingredients like Zn, Cr etc. is a common issue during plasma-assisted atomization.

The filling device means there is no need to open the melting chamber for refilling. This way, the melting chamber temperature remains high and unnecessary loss of energy is avoided. Most importantly: No oxygen enters the melting chamber so the chamber does not need to be evacuated again and refilled with inert gas. The advantages: lower personnel costs, more consistent casting quality, better process stability, less waste, optimised overlapping casting, up to 20 casting cycles per hour, high energy efficiency, longer service lives for consumables, minimised metal loss, replenishment without loss of pressure.

Numerous measures in our casting systems reduce metal losses during the casting process to an absolute minimum. These include, among other things, the sophisticated overpressure and vacuum controls, the anti-oxidation system, the vibration system and, last but not least, the high-quality materials of the crucibles and sealing rods.

No need for complex and expensive wire production as feedstock material for atomizing, which is time-consuming and requires additional infrastructure like continuous casting machines, a drawing bench etc.

Remote control function available. Optional upgrade features like gates for powder supply and the conveying of powder, special filter systems and interfaces to connect to your powder receivers.

for evaporated alloy ingredients otherwise caused by plasma melting

Up to 20 casting cycles per hour thanks to programmable overlapping casting and optional automatic feeding devices.

Sintering/diffusion bonding is the optimum process for producing multi-coloured rings, mostly sold as wedding rings, or bracelets. Metals are processed under pressure and at temperatures below the solidification point. The pressure is generated pneumatically and not mechanically via a threaded spindle. This means that there is no risk of graphite parts breaking as a result of heat expansion. The fusion between layers has the same durability as the metal itself. The sintering kit is ideal for the occasional diffusion bonding job and for smaller series production.

All process parameters can be set individually and saved for repeated castings.

zur Vermeidung von Metallverlusten oder Querkontamination

Straightforward installation/removal of the rings.

Very simple and safe to operate, short training periods.

The easy to install granulation tank makes each CC machine even more versatile. CC 400 and VCC 400 are furthermore offering a third application possibility: with the sintering kit you can use this machine for diffusion bonding,e.g. for the production of multi-layer rings.

In development: e.g. larger version offering a crucible volume of 1.5 l

Yield for example for Bronze d50= 40-60 µm. Bronze throughput up to several kg/h.Very small batch sizes down to ~100 g technically and financially viable.

Alloying with a good stirring/mixing effect due to strong medium- frequency induction generator with simultaneous high heating efficiency. Melting under vacuum or inert gas atmosphere and atomizing under inert gas atmosphere.

by use of different atomisation nozzles and optional use of hot spray gas Modular availability of free fall as well as close coupled atomisation nozzles to obtain specific metal powder characteristics. Fast and easy nozzle change.

Find more about VTC-Series

VTC 100 – 800 V Ti high vacuum casting machines

Highly reactive metals such as titanium pose particular challenges when casting. The atmospheric conditions in a ‘normal’ vacuum pressure casting machine are completely inadequate for smelting and casting titanium, and the crucibles and moulds need to be made of specific materials.

Hence until now the only way to cast titanium was to use extremely expensive specialised machines. As part of a joint AiF ZIM research project, Indutherm has collaborated with FEM (Schwaebisch Gmuend) under the sponsorship of the Federal Ministry for Economics and Technology (Bundesministeriums für Wirtschaft und Technologie – BMWi) to develop a cost-effective solution for casting highly reactive metals. The ideal structural basis proved to be the VTC 200 V tilting casting machine.

Following numerous modifications, such as completely reconstructed valves and hose connections, special seals and an evacuation and inert gas flushing process tailored to the machine, the prerequisites for the required vacuum of 10-7 bar were met. Furthermore, special crucibles and inductors were developed for the Ti versions, as the ceramic crucibles that are normally used also react with titanium to varying degrees. The new materials also reduce smelting times – and the shorter the smelting time, the less time there is for a possible reaction.

The VTC V Ti machines are not only suitable for casting titanium – they can also be used for any highly reactive metal or alloy, such as copper beryllium etc.

Every model in the VTC range from the VTC 100 V to the VTC 800 V is available in a Ti version.

More Informations about VTC-Series

Download catalogue (pdf)

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