Investment Foundry

TYPES OF FOUNDRY TYPES OF FOUNDRY 1. Sand Foundry 1. Sand Foundry 2. Investment Foundry 2. Investment Foundry Investment Foundry Process Investment Foundry Process Wax Preparation Wax Preparation 1. Riser Wax – More load applied and good sticking ability. 1. Riser Wax – More load applied and good sticking ability. Maintaining temp – 100 to 110 deg. Maintaining temp – 100 to 110 deg. 2. Product Wax – Less load applied strength and low sticking ability. Its depend upon the preparation. Because easy releasing into the mould. 2. Product Wax – Less load applied strength and low sticking ability. Its depend upon the preparation. Because easy releasing into the mould. Maintaining temp – 45 to 55 deg. Maintaining temp – 45 to 55 deg.

Investment Foundry Wax Injection Wax Injection Mainly needed Mainly needed Cooling water and mould releasing spray. Cooling water and mould releasing spray. Different types of mould. Different types of mould.

Investment Foundry Wax Assembly Wax Assembly Mainly needed Mainly needed Sticking wax and Knife. Sticking wax and Knife. Heating equipments Heating equipments The wax patterns are assembled into "trees" by fusing the parts to be cast with gates, risers, vents, and pour cups as needed for casting. The wax patterns are assembled into "trees" by fusing the parts to be cast with gates, risers, vents, and pour cups as needed for casting.

Investment Foundry Shelling Process Shelling Process Mainly needed Mainly needed Coating slurry – First coating and Second coating Coating slurry – First coating and Second coating Conveyor Conveyor Fully air conditioned room. Maintaining temp – 17 to 20 deg Fully air conditioned room. Maintaining temp – 17 to 20 deg This tree is finished and ready for shelling. The pathways for the molten metal are laid out and attached to the part to accommodate both filling and feeding of each part. This tree is finished and ready for shelling. The pathways for the molten metal are laid out and attached to the part to accommodate both filling and feeding of each part. The finished trees are coated with a refractory ceramic shell. They are dipped into a colloidal silica slurry and then covered with a zircon and/or fused silica stucco (sand). This process starts with a fine slurry and zircon sand for a good surface finish and low reactivity. The dipping progresses through stages of coarser slurry and stucco until a thick shell has formed around the wax tree. The finished trees are coated with a refractory ceramic shell. They are dipped into a colloidal silica slurry and then covered with a zircon and/or fused silica stucco (sand). This process starts with a fine slurry and zircon sand for a good surface finish and low reactivity. The dipping progresses through stages of coarser slurry and stucco until a thick shell has formed around the wax tree.

Investment Foundry Dewaxing Dewaxing When the shelling process is finished and the shells have completely dried, the wax is removed under steam heat and pressure in an autoclave. When the shelling process is finished and the shells have completely dried, the wax is removed under steam heat and pressure in an autoclave.

Investment Foundry Melting and Pouring Melting and Pouring Melting for both investment and sand casting is performed using electric induction furnaces. Two 400 pound capacity box furnaces handle the larger pours. A smaller lift coil with a 200 pound capacity is used for alloys with lower melting points such as aluminum and brass. It is also used for smaller pours of non-ferrous alloys to reduce waste. All alloys are QC checked on our spectrometer prior to pouring and adjusted to insure conformance with specifications. Melting for both investment and sand casting is performed using electric induction furnaces. Two 400 pound capacity box furnaces handle the larger pours. A smaller lift coil with a 200 pound capacity is used for alloys with lower melting points such as aluminum and brass. It is also used for smaller pours of non-ferrous alloys to reduce waste. All alloys are QC checked on our spectrometer prior to pouring and adjusted to insure conformance with specifications. Investment shells are pre-heated in a kiln before pouring to insure proper filling and minimize casting defects. Investment shells are pre-heated in a kiln before pouring to insure proper filling and minimize casting defects.Investment

Investment Foundry The molten metal from the box furnace is poured into a pre-heated ladle that is used to pour the molds. The lift coil furnace melts alloys in a crucible that is also used for pouring. The use of separate crucibles for each base alloy prevents cross contamination of the metals. The molten metal from the box furnace is poured into a pre-heated ladle that is used to pour the molds. The lift coil furnace melts alloys in a crucible that is also used for pouring. The use of separate crucibles for each base alloy prevents cross contamination of the metals. Ceramic and glass cloth filters are used in each mold to eliminate impurities and inclusion from the metal as it is cast Ceramic and glass cloth filters are used in each mold to eliminate impurities and inclusion from the metal as it is cast

Investment Foundry Knock out process Knock out process Fully ceramic cleaning process Fully ceramic cleaning process

Investment Foundry Fettling process (Finishing) Fettling process (Finishing) and and Heat Treatment process Heat Treatment process

Investment Foundry Benefits of the Process Benefits of the Process The benefits of the investment casting process may be summed up by the four words accuracy, versatility, integrity and finish. The benefits of the investment casting process may be summed up by the four words accuracy, versatility, integrity and finish. Other advantages arise from the high degree of dimensional accuracy Other advantages arise from the high degree of dimensional accuracy Future Potential & Development Future Potential & Development With the development of rapid prototyping techniques for the production of patterns and shells it is now possible to produce investment castings quickly with lead times reduced to less than two weeks. With the development of rapid prototyping techniques for the production of patterns and shells it is now possible to produce investment castings quickly with lead times reduced to less than two weeks.

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