Wax Workmanship Standards

Original Author: Nicole Leavitt

Form: wax-f-003
Rev Date: 12/9/2015

Table of Contents
Part & Injection Defects ...................................................................................................................................................................2
Air/ Air Pockets...4
Breakage .......................................................................................................................................................................................4
Chill Breakthrough........................................................................................................................................................................5
Cracks ...........................................................................................................................................................................................6
Debris ...........................................................................................................................................................................................7
Dimensional..................................................................................................................................................................................8
Distortion......................................................................................................................................................................................9
Flash .......................................................................................................................................................................................... 10
Flow Lines .................................................................................................................................................................................. 11
Incorrect Identification.............................................................................................................................................................. 12
Negatives ................................................................................................................................................................................... 13
Positives..................................................................................................................................................................................... 14
Tooling Marks/Offsets ............................................................................................................................................................... 15

Form: wax-f-003
Rev Date: 08/25/2015

Part & Injection

Defects

Form: wax-f-003
Rev Date: 08/25/2015

Air/ Air pockets

DESCRIPTION:
Various shapes and sizes of air exposed to the surface of a wax component
CAUSES:
Air trapped in the wax component or in the fusing wax
EFFECT:
1. May cause ceramic inclusions also known as chips
2. Dimensional integrity of wax component may be affected
REJECTABLE IF:
1. Found on a part and cause any negative or positives on the part surface
2. The pockets have not been opened and filled with wax
3. The pockets cause poor surface finish or rough surface on the part
ACTION REQUIRED:
1. If there is excessive air found on an injected part, the part must be discarded and a new part ran in its place.
2. If little air is found on the surface of a part, the part can be repaired by opening the air pockets, filling the
negative with patch wax and smoothing the surface flush to the part feature.
3. If air/ air pockets are a constant problem on a specific part, inform the area supervisor or the part engineer of
the issue.

Air pockets found in a Steel part. If the air is found on

the part surface there is the possibility of air
entrapment throughout the entire wax part.

Air pockets found in an Aluminum part. All pockets must

be opened and filled like the part shown above so no air is
present on the surface of the part.
3

Form: wax-f-003
Rev Date: 08/25/2015

Breakage
DESCRIPTION:
Permanent mutilation or displacement of a part surface or feature
CAUSES:
Improper handling
Operator Error
EFFECT:
1. Dimensional errors and non-compliance of customer specifications
2. Additional rework
REJECTABLE IF:
1. Any feature has been completely removed from the part
2. There is an offset of any part surface
3. Not PVN'ed and passed off by engineering for further processing
ACTION REQUIRED:
1. If a broken part is found the part must be discarded and another injected it its place.
2. If parts are continually breaking when being removed from the injection tool, inform the area supervisor or the
part engineer of the issue.
3. If engineering approved a repair of a broken part, the repaired part requires a PVN with engineering approval to
move through production.
Gate which was broken
off the part and took a
section of the part with
it. This is not acceptable
and will cause
dimensional issues in
the backend. The part
was scrapped.

Parts which have been

broken to the point where
features have been
completely removed are
hard to repair because
there is no guarantee the
feature was placed back
within the customers
dimensions. This is not an
acceptable repair.

Example of a
part feature
which has been
broken all the
way through.
This part is not
acceptable for
assembly use
and needs to be
replaced with
another part
which is not
broken.

This part was repaired using a technique called stitchingMelting of lines perpendicular to the crack and filling in
the negatives until the surface is flush.

Form: wax-f-003
Rev Date:Form:
08/25/2015
wax-f-003
Rev Date: 08/25/2015

Chill Breakthrough
DESCRIPTION:
Opening in the surface of the wax part to which the wax chill insert can be seen
CAUSES:
Improper chill size or shifting of the chill during the injection process
EFFECT:
1. Can cause a surface offset on the face of the part resulting in dimensional or surface finish issues
2. Can cause investment traps which may result in chips
REJECTABLE IF:
1. There is any positive or negative in the surface of the part
2. If the breakthrough causes any sharp edges to be present
3. If the breakthrough disrupts the natural flow of a feature of a part which would result in dimensional failure
ACTION REQUIRED:
1. Any positive or negative surfaces caused by chill breakthrough must be made flush to the part feature.
2. Any sharp edges caused by breakthrough must be broken and cleaned until there are no sharp edges present.
3. If the chill breakthrough disrupts a part distorting the part beyond repair, a new part must be injected in its
place.
Large chill
breakthrough
area found
on an
aluminum
part.

Chill breakthrough in a steel part left by a large chill

insert.

Chills like these can leave a chill breakthrough

pattern in the part as shown to the right.
5

Form: wax-f-003
Rev Date: Form:
08/25/2015
wax-f-003
Rev Date: 08/25/2015

Cracks
DESCRIPTION:
Separation of the wax surface or a separation visible through the wax surface
CAUSES:
Handling damage or stress of a wax component
EFFECT:
1. Investment trap may be created producing chips in the casting
2. Failure of wax component.
REJECTABLE IF:
4. Cracks are resent anywhere on the part or gating
5. The crack goes through a feature but the crack cannot be repaired on both side of the feature
6. The crack causes an offset of the surface and cannot be repaired flush
ACTION REQUIRED:
1. All broken parts that have been repaired require engineering approval to move through production. No
acceptations to this policy.
2. Crack must be repaired on both sides of the cracked feature in order to be acceptable.
3. Crack must be sealed along the entire length of the crack and be flush with the part, no negatives or positives.
Cracks which
are not
properly
repaired can
result in a weak
area forming in
the cast metal
part.

Small cracks such as this can be fixed

by painting the surface and then
making the wax flush with the part.

Cracks in an
Aluminum
wax part
which has
been
repaired. This
is acceptable
as long as the
part surface is
flush and no
negatives or
holes are
present.

Steel part which

was cracked
filled with wax
and smoothed
on both sides of
the cracked
feature. This is
acceptable as
long as there was
no offset of the
cracked surface.

Form: wax-f-003
Rev Date: 08/25/2015

Debris
DESCRIPTION:
All material which is not intended to be part of the wax component
CAUSES:
Loose particles of wax from wax operations
Improper cleaning and upkeep of work areas, tools, fixtures, etc.
EFFECT:
1. Chips in the casting causing additional rework or possibly scrapping of the part
2. Additional cleaning of parts, areas, machinery, or materials in further processes or departments
REJECTABLE IF:
1. Any loose material is found on or in the part or setup
2. The debris is imbedded in the part and cannot be easily removed or cleaned from the part
ACTION REQUIRED:
1. Loose material can be cleaned from a part by using an air gun at a low PSI.
2. If the debris is embedded in any surface of the part, remove the debris and fill in the negative area caused from
removing the debris.
3. If debris on a part is excessive and cannot quickly and easily be removed, a new part must be injected in its
place.
Excessive use of
Treewax used to
smooth a parts
surface can lead
to cracking of the
wax. If found this
will be handled as
debris on the part
surface.

Soluble fibers remaining on setups

after leach out will be considered
debris

Wax flakes found on steel part.

Wax flakes found on Aluminum part.

7

Form: wax-f-003
Rev Date: 08/25/2015

Dimensional
DESCRIPTION:
Any dimensional irregularity not seen with the naked eye but discovered through SPC dimensional checks
CAUSES:
Improper handling of part when being removed from injection tool
Improper storage of part or improper support of part during the cooling process
Tool wear, improper tool design, improper tool assembly or improper tool upkeep
EFFECT:
1. Dimensional integrity of the wax pattern may be affected
2. Additional rework of the casting may be required
3. Part may be scrapped in further processes for not conforming to the customers dimensional callouts
REJECTABLE IF:
1. Recorded dimension does not fall within the spec limits called out by the part engineer for SPC measurements
ACTION REQUIRED:
1. If a part fails a dimensional SPC check, the part must be discarded and a new part injected in its place.
2. If dimensional problems are a constant issue on a part, inform the area supervisor or the part engineer of the
issue.
Example
of DPC
screen.
DPC is one
of the
data bases
used to
record
dimension
al data.

Form: wax-f-003
Rev Date: 08/25/2015

Distortion
DESCRIPTION:
Visible inconsistency in the makeup of a parts geometry
CAUSES:
Improper handling of part when being removed from injection tool
Improper storage of part or improper support of part during the cooling process
EFFECT:
1. Dimensional integrity of the wax pattern may be affected
2. Additional rework of the casting may be required
3. Part may be scrapped in further processes
REJECTABLE IF:
1. Any notice of distortion is found on a part
ACTION REQUIRED:
1. If any distortion is found on a part, the part must be discarded and a new part injected in its place.
2. If distortion is a constant issue on a part, inform the area supervisor or the part engineer of the issue.
External
diameter of
the part has
been distorted
due to
improper
removal of the
wax pattern
from the
injection tool.
Top features is bowed not flat

Flatness where there should be a radius

9

Form: wax-f-003
Rev Date: 08/25/2015

Flash
DESCRIPTION:
A fine or abrupt edge on a wax component terminating in a point
CAUSES:
Tool wear, improper tool design or improper tool upkeep
EFFECT:
1. Shell crack or buckle may be created producing chips in the casting
2. Dimensional integrity of wax component may be affected
REJECTABLE IF:
1. The flash or parting line is not cleaned flush to the part surface resulting in a positive or negative on the part
2. The flash or parting line causes a thin, flimsy wax wall to be present
ACTION REQUIRED:
1. If there is excessive flash or parting lines on an injected part which cause it to be unrepairable, the part must be
discarded and a new part injected in its place.
2. All flash or parting lines must be cleaned from the part. Part surface must be flush with original features.
3. If flash/ parting lines are a constant problem on a specific part, inform the area supervisor or the part engineer
of the issue.
Flash found
on an
aluminum
part.
Classified as
a sharp
edge.

Parting lines
which are not
cleaned from
the parts are
classified as
sharp edge
and can
create
investment
traps.

Flash present on a steel

test bar. Classified as a
sharp edge.

Sharp edges/ parting lines have been

smoothed. This is a proper cleaned part.
10

Form: wax-f-003
Rev Date: 08/25/2015

Flow Lines
DESCRIPTION:
A wavy indication on the surface of the pattern causing an unusual surface finish
CAUSES:
Too much lube accumulation in the wax tool
Wax was too cold when injected into the tool
Tool was too cold during the injection process
EFFECT:
1. Dimensional integrity of wax component may be affected
2. Surface finish requirements may not be met

REJECTABLE IF:
1. Flow lines are present on any surface of the part

ACTION REQUIRED:
1. Tool must be cleaned and all lube removed.
2. Verify lube gun is not out of adjustment.
3. Contact supervisor, lead or engineering if condition persists.

Flow lines, wavy area in part causing poor surface

finish
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Form: wax-f-003
Rev Date: 08/25/2015

Incorrect Identification
DESCRIPTION:
Parts that do not have proper job number, serial number, lot number or injectors initials
CAUSES:
Operator failed to perform task correctly, lack of training
EFFECT:
1. Lack of traceability
2. Lack of accountability
REJECTABLE IF:
1. Any of the required information is missing. All parts must be marked with job#, lot# and operator initials

ACTION REQUIRED:
1. If possible, mark parts correctly.
2. If not possible to identify traceability information, parts must be rejected and scrapped.

LEFT: The number 8

at the end was
accidently stamped
as a 3, so to try to
fix it, it was then
stamped with a
backwards 3.This is
unacceptable.

Part marking location: anywhere on the part to

include job number, lot and operators initials.

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Form: wax-f-003
Rev Date: 08/25/2015

Negatives
DESCRIPTION:
A depression of the wax surface
CAUSES:
1. Positive in the die.
2. Human error when cleaning or handling parts
EFFECT:
1. Dimensional integrity of wax component may be affected
2. Additional rework of the casting.
REJECTABLE IF:
1. The negative > .005 is found on any surface of the part, or if a negative if found which has not been properly
repaired
2. If the negative results in a rough surface finish or sharp edge on part
ACTION REQUIRED:
1. Pattern must be repaired flush to the adjacent surfaces with red or green wax.
2. If unsure, contact engineering to evaluate.

Negative
found near
the injection
point of a
steel part.
Injections
should be
smoothed
flush.

Negative in an
injected steel
part caused
by a finger
nail while the
part was still
warm.

Parting line was

scraped from
an aluminum
part causing a
negative in the
part. The
negative was
filled and the
surface made
flush. This is an
acceptable
negative repair.

Proper filling of a negative. After

filling negative, it was properly
smoothed flush to part.

13

Form: wax-f-003
Rev Date: 08/25/2015
Form: wax-f-003
Rev Date: 08/25/2015

Positives
DESCRIPTION:
An area raised above the normal wax surface
CAUSES:
1. Internal trapped air
2. Negative in the soluble core and or die
EFFECT:
1. Dimensional integrity of the wax pattern may be affected
2. Additional rework of the casting
REJECTABLE IF:
1. A positive greater than .005 is found on any surface of the part, or if a positive if found which has not been
properly repaired
2. If the positive results in a rough surface finish or sharp edge on part
ACTION REQUIRED:
1. Remove positive and make area flush to adjacent surfaces.
2. If unsure, contact engineering to evaluate.
Typical
positive
found on an
Aluminum
part.

Injection
stubs which
are not
completely
removed and
taken flush
to the part
will be
classified as
positives.

14

Form: wax-f-003
Rev Date: 08/25/2015

Tooling Marks/Offsets
DESCRIPTION:
Offset condition along the parting line >.005, distorting the shape of the wax component
CAUSES:
Tool wear, improper tool design, improper tool assembly or improper tool upkeep
EFFECT:
1. Dimensional integrity of the wax pattern may be affected
2. Additional rework of the casting
REJECTABLE IF:
1. Mismatch is >.005
2. If tooling marks create a negative <.005
ACTION REQUIRED:
1. Refer to positive and negatives requirements.
2. If tooling marks/ offsets are a constant problem on a specific part, inform the area supervisor or the part
engineer of the issue.
Positive
(Left) and
Negative
(Right)
tooling
offsets seen
in the cast
metal part.
Small negative surface on the part caused by the
ejector pins which push the part out of the tool.

Surface
offsets
caused by
the tooling.
These need
to be
cleaned and
the surface
made flush.
Large surface offset cause by tooling. Back surface should
be flush and has a very clear raised section in the part.

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Form: wax-f-003
Rev Date: 08/25/2015

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Form: wax-f-003
Rev Date: 08/25/2015