An Overview of the Precision Investment Casting Process Steps and Phases | GEMSO

1. WELCOME An Overview of the Precision Investment Casting Process Steps and Phases

2. Introduction • One of the oldest methods of making metal precision components is investment casting. The process starts with the creation of a wax pattern, which is a steel replica of the required component. • The design is encased in a ceramic material, which is then heated to remove it. After that, molten steel will be poured into the mold's opening. After the solid steel mould has been ripped away, the casting is ready to use. • Investment castings are made using a method called investment casting. • The process begins with the creation of the master pattern. To create the one-of-a-kind pattern, the artist could use wax, clay, steel, plastic, or wood. He'll be able to make the mould or master die after that. • This one is made of metal, steel, or metal. The steps and phases of investment casting are listed below.

3. STEPS INVOLVED IN INVESTMENT CASTING • TOOLING • Dies are made by skilled tool room technicians using CNC machining and EDM procedures. • The majority of investment tools are composed of aluminum and have brass or steel cores as well as retractable slides. • INJECTION OF WAX PATTERN • To ensure dimensional homogeneity, liquid pattern wax is injected under temperature/pressure controlled conditions from the first to the hundredth injection cycle. • When the wax construction has set, it can be readily removed from the die. • ASSEMBLING THE STRUCTURE • After that, the wax drawings are attached to a wax runner system, which allows the molten metal to flow freely. • Using over 30 basic designs of runners, castings of varied sizes and sections can be built to a high degree of precision.

4. Continue… • Making Molds • Following the completion and cleaning of the wax assemblies, a ceramic shell is constructed by repeatedly dipping the wax assembly in a liquid ceramic slurry and then coating it with ceramic stucco. • The shell-making robot technology used to invest the assemblies is completely automated. The investment shell is built up in stages until it reaches a thickness that is thick enough to withstand the pouring's thermal stresses. • De-Waxing • The wax is steamed away from the investment shell in a steam pressure vessel, leaving the negative hollow spaces of the components within. • Fire the Mould • To remove wax residue, boost mechanical strength, and preheat in preparation for the casting process, Ceramic Shell moulds are burned at 1000°C.

5. Continue… • Coating of Shells • In Shell coating, the pattern assembly will be dipped in a ceramic slurry and coated with a refractory material. • Rep this process until the desired thickness and strength are achieved. After that, the ceramic shell is finished and placed in an atmosphere-controlled chamber to dry. • Finishing • After the metal has been set, the ceramic mould is removed and cleaned with pneumatic vibratory machinery. • In preparation for heat treatment or quality assurance, the castings are cut away from the runner, fettled, and shot blasted. • Treatment with Heat • As cast constructions, castings are heat-treated to improve mechanical characteristics, machinability, and homogeneity. • Heat treatment is carried out on-site in atmosphere-controlled furnaces.

6. Conclusion • In the power generation and aerospace industries, investment castings are widely employed. • They're utilized to make intricate structures for turbine blades and cooling systems, among other things. Blades that are directionally solidified, generally equated, and single-crystal are among the most common blades produced by the process. • Military, medical, automotive, and commercial applications all require investment castings.