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The vacuum sand casting process begins with the preparation of a sand mold, which is typically made of a mixture of sand and a binding agent. In traditional sand casting, the mold is often subject to atmospheric pressure, which can lead to defects such as gas porosity and inclusions in the final cast product. Vacuum sand casting, however, mitigates these issues by creating a vacuum inside the mold cavity before the molten metal is poured.

Despite its many advantages, aluminum alloy die casting is not without challenges. The initial costs associated with mold production can be high, making it more suitable for high-volume production runs. Additionally, the process requires careful control of variables such as temperature and pressure to avoid defects such as porosity or dimensional inaccuracies. Nevertheless, with advancements in technology and materials science, many of these challenges are being addressed, ensuring the continued growth of aluminum die casting in various sectors.