Casting
Investment Casting
Investment casting is a manufacturing process in which a wax pattern is coated with a refractory ceramic material. Once the ceramic coating material is dry and hardened, the wax is melted out and leaves an internal cavity the shape of the final product’s geometry. Molten metal is poured into the cavity where the wax pattern was. The metal solidifies within the ceramic cavity, cools, and the ceramic is removed from the metal casting. The result of this process is a net to near-net precision metal component which can be used for a broad range of applications in various industries.
There are several specific steps in the entire process to design and create the desired workpieces.
Investment Casting process flow
1. Casting Simulation
4. Wax Pattern Assembly
7. Pouring
2. Master Pattern & Die Making
5. Shell Mould Production
8. Knockout
3. Wax Pattern Production
6. Shell Dewaxing
9. Heat Treatment
10. Fettling
11. Machining
12. Shipment
Investment Casting process benefits
Investment Casting has also its benefits, such as:
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Smooth Finish: Investment casting uses a ceramic mold that can produce a much smoother finish, typically averaging 125 RA surface finish as cast.
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Faster Production: Investment castings cut down on labor time and produce quicker lead times because it greatly reduces the amount of machining required after casting.
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Tight Tolerances: Investment castings hold tighter tolerances, which reduces the amount of machining required. The standard tolerance is +/-.005 per inch.
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Affordable Tooling: Investment casting requires less expensive equipment and is inherently less dangerous, which allows for costs to remain low.
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Vast Size Range: Investment casting allows for both large and small casts. Intricate, miniature parts that are 5 grams or less can be cast, and also large parts up to 23 kgs can be cast.
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Material Variety: There are a variety of materials that can be used for investment casting which range from bronze, stainless steel, and even aluminum.