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Investment Foundry Investment Foundry

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Page 1: 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 Investment Foundry

Page 2: Investment Foundry. TYPES OF FOUNDRY TYPES OF FOUNDRY 1. Sand Foundry 1. Sand Foundry 2. Investment Foundry 2. Investment Foundry Investment Foundry Process

Investment FoundryInvestment Foundry TYPES OF FOUNDRY TYPES OF FOUNDRY 1. Sand Foundry1. Sand Foundry 2. Investment Foundry2. Investment Foundry

Investment Foundry ProcessInvestment 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 2. Product Wax – Less load applied strength and low sticking ability. Its depend upon the preparation. Because easy releasing into the mould. the preparation. Because easy releasing into the mould.

Maintaining temp – 45 to 55 deg.Maintaining temp – 45 to 55 deg.

Page 3: Investment Foundry. TYPES OF FOUNDRY TYPES OF FOUNDRY 1. Sand Foundry 1. Sand Foundry 2. Investment Foundry 2. Investment Foundry Investment Foundry Process

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

Page 4: Investment Foundry. TYPES OF FOUNDRY TYPES OF FOUNDRY 1. Sand Foundry 1. Sand Foundry 2. Investment Foundry 2. Investment Foundry Investment Foundry Process

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

Page 5: Investment Foundry. TYPES OF FOUNDRY TYPES OF FOUNDRY 1. Sand Foundry 1. Sand Foundry 2. Investment Foundry 2. Investment Foundry Investment Foundry Process

Investment FoundryInvestment Foundry Shelling ProcessShelling Process Mainly neededMainly needed Coating slurry – First coating and Second coatingCoating slurry – First coating and Second coating ConveyorConveyor Fully air conditioned room. Maintaining temp – 17 to 20 degFully 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 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.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 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). 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 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 reactivity. The dipping progresses through stages of coarser slurry and stucco until a

thick shell  has formed around the wax tree.thick shell  has formed around the wax tree.

Page 6: Investment Foundry. TYPES OF FOUNDRY TYPES OF FOUNDRY 1. Sand Foundry 1. Sand Foundry 2. Investment Foundry 2. Investment Foundry Investment Foundry Process

Investment FoundryInvestment Foundry DewaxingDewaxing

          When the shelling process is finished and the shells have completely When the shelling process is finished and the shells have completely

dried, the wax is removed under steam heat and pressure in an autoclave.dried, the wax is removed under steam heat and pressure in an autoclave.

Page 7: Investment Foundry. TYPES OF FOUNDRY TYPES OF FOUNDRY 1. Sand Foundry 1. Sand Foundry 2. Investment Foundry 2. Investment Foundry Investment Foundry Process

Investment FoundryInvestment Foundry Melting and PouringMelting and Pouring           Melting for both investment and sand casting is performed using electric induction 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 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 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 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 waste. All alloys are QC checked on our spectrometer prior to pouring and adjusted to insure conformance with specifications.to insure conformance with specifications.

      InvestmentInvestment shells are pre-heated in a kiln before pouring to insure proper filling and shells are pre-heated in a kiln before pouring to insure proper filling and minimize casting defects. minimize casting defects.

Page 8: Investment Foundry. TYPES OF FOUNDRY TYPES OF FOUNDRY 1. Sand Foundry 1. Sand Foundry 2. Investment Foundry 2. Investment Foundry Investment Foundry Process

Investment FoundryInvestment Foundry

          The molten metal from the box furnace is poured into a pre-heated ladle that is 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 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 for pouring. The use of separate crucibles for each base alloy prevents cross contamination of the metals.contamination of the metals.

Ceramic and glass cloth filters are used in each mold to eliminate impurities and Ceramic and glass cloth filters are used in each mold to eliminate impurities and inclusion from the metal as it is cast inclusion from the metal as it is cast

Page 9: Investment Foundry. TYPES OF FOUNDRY TYPES OF FOUNDRY 1. Sand Foundry 1. Sand Foundry 2. Investment Foundry 2. Investment Foundry Investment Foundry Process

Investment FoundryInvestment Foundry Knock out processKnock out process Fully ceramic cleaning processFully ceramic cleaning process

Page 10: Investment Foundry. TYPES OF FOUNDRY TYPES OF FOUNDRY 1. Sand Foundry 1. Sand Foundry 2. Investment Foundry 2. Investment Foundry Investment Foundry Process

Investment FoundryInvestment Foundry Fettling process (Finishing)Fettling process (Finishing) andand Heat Treatment processHeat Treatment process

Page 11: Investment Foundry. TYPES OF FOUNDRY TYPES OF FOUNDRY 1. Sand Foundry 1. Sand Foundry 2. Investment Foundry 2. Investment Foundry Investment Foundry Process

Investment FoundryInvestment Foundry

Benefits of the Process Benefits of the Process The benefits of the investment casting process may be summed The benefits of the investment casting process may be summed

up by the four words accuracy, versatility, integrity and finish.up by the four words accuracy, versatility, integrity and finish.

Other advantages arise from the high degree of dimensional accuracyOther advantages arise from the high degree of dimensional accuracy

Future Potential & DevelopmentFuture Potential & Development With the development of rapid prototyping techniques for the production of With the development of rapid prototyping techniques for the production of

patterns and shells it is now possible to produce investment castings patterns and shells it is now possible to produce investment castings quickly with lead times reduced to less than two weeks.quickly with lead times reduced to less than two weeks.

Page 12: Investment Foundry. TYPES OF FOUNDRY TYPES OF FOUNDRY 1. Sand Foundry 1. Sand Foundry 2. Investment Foundry 2. Investment Foundry Investment Foundry Process

Thank YouThank You