Process Cycle

The casting materials can be widely used and no limit to product shape as well as complex structure. Investment casting allows for closer tolerance control, lower or no machining allowance, and better surface finish. Also called lost wax casting, the process enables to improve the dimensional precision and surface finish, so as to meet the requirements of a higher level product. We have divided into 4 stages as below:

Stage  1

  • Wax Injection

    Wax Injection

    The process begins with production of a heat disposable pattern. This is usually made by injecting wax into a metal die or mold. At the end of this stage the pattern is injected in Horizontal or Vertical Automatic Injection Machine.

  • Pattern Assembly

    Pattern Assembly

    The wax pattern is attached by the gate to a central wax runner system called spruce. Patterns, runners, and pouring cup compromise the cluster or tree. Radius is provided to all joints between pattern and runner.

  • Shell Building

    Shell Building

    The assembly is dipped into a ceramic slurry and then into a bed of extremely fine sand. After drying, the process is repeated. Up to 4 to 6 layers may be applied in this manner, depending on product requirement to ensure appropriate shell.

Stage  2

  • Dewaxing

    Dewaxing

    The completed shell is placed in a steam autoclave where the pattern melts and runs out through the gates and pouring cup.

  • Preheat

    Preheat

    The ceramic shell molds is fired to burn out the last traces of pattern material in preparation for casting, usually in the range of 800° C to 1100° C.

  • Casting

    Casting

    The preheated shell is filled with molten metal by gravity pouring. As the metal cools, the parts, gates, spruce and pouring cup give a solid cast.

Stage  3

  • Shell Removal

    Shell Removal

    After the metal solidifies and cools, the ceramic shell is removed by vibratory methods.

  • Shot Blast & Cut Off

    Shot Blast & Cut Off

    Cast is shot blasted to remove all small ceramic particles. Individual casting is removed from the cluster by means of a cut off wheel or welding cut.

Stage  4

  • Gate Grinding

    Gate Grinding

    Remaining gate protrusions are removed by belt grinding and heat treated as required. The cast is sand blasted / shot blasted as per specification.

  • Final Quality Checks

    Final Quality Checks

    Cast is shot blasted to remove all small ceramic particles. Individual casting is removed from the cluster by means of a cut off wheel or welding cut.

  • Dispatch

    Dispatch

    Product is packed and dispatched.