LATEST TRENDS

IN INVESTMENT CASTING TECHNOLOGY

Dr.Ing.Milan Horáček,PhD Brno University of Technology, CZ

PAPER STRUCTURE

A/ Survey of foundry technologies available for casting manufacture

B/ Basic principles of lost wax process – investment casting

C/ Brief history of the investment casting technology

D/ Description of individual investment casting process phases

- wax pattern manufacture
- ceramic shell manufacture
- de-waxing
- shell heat treatment
- metal pouring
- finishing operations

E/ Accuracy of investment casting technology

F/ Capabilities of modern lost wax technology (examples of castings)

A/ SURVEY OF CASTING TECHNOLOGIES USING SAND MOULDING

Ist . GENERATION - clay binders

IInd. GENERATION – chemical binding
a/ Self-hardening processes (plaster,cement,sodium silicate,resin)

b/ External hardening processes (sodium silicate, resin)

c/ Ceramic moulds (mould firing before pouring)

1. Permanent pattern 2. „Lost“ pattern

LOST FOAM LOST WAX

IIIrd. GENERATION – physical binding

B/ BASIC INVESTMENT CASTING PROCESS
Wax pattern making Wax pattern assembly Dipping into ceramic
Wax slurry
pattern
Die

Wax pattern

Gating system

Ceramic coating Finished shell De-waxing

Ceramic shell

Metal pouring Removal of shell Casting cut-off

C/ BRIEF HISTORY OF LOST-WAX PROCESS

p.n.l – 0 – n.l 5000 4000 3000 2000 1000 0 1000 2000

Thajsko
Mezopotámie
Izrael
Indie/S.V. Asie
Anatólie
Čína
Egej / Řecko
Etrusko
Keltská S. Evropa
Římané
Jižní/Střední Amerika
Západní Afrika
Západní Evropa
Renesanční Itálie
 EXAMPLES OF HISTORICAL CASTINGS

gold comb casting

(300g, Dniepr area, 4th cent.A.D.)

bronze head (Benin – 12th.cent.A.D.)

bronze statue of Perseus with Meduza head

(Cellini, 1540)
D/ DESCRIPTION OF INDIVIDUAL PHASES OF INVESTMENT CASTING PROCESS

1. WAX PATTERN MANUFACTURE

a/ Die manufacture
b/ Wax pattern injection
c/ Pattern assembly

2. CERAMIC SHELL MANUFACTURE

a/ Step-by-step shell building and drying

b/ Shell de-waxing
c/ Ceramic shell firing

3. METAL POURING

a/ On air
b/ Under vacuum

4. FINISHING OPERATIONS
a/ Gating system removal
b/ Surface finish cleaning, blasting, etc.
 1. WAX PATTERN MANUFACTURE
a/ Master die making
-Using master pattern
(using low-melt point alloys, by metal spraying, by galvanization)

METAL SPRAYING
Master pattern
Master die

Sand mould

Low melting point alloy

Plaster

Low melting point alloy GALVANIZATION

Sn,Bi,Pb,Cd Low melting point alloy
Tmel=70°C Metal master
soft pattern
Tmel= 138°C
hard
Ni,Cu,Fe
Master die by galvanization

-By machining from solid metal blocks

( the most often used method )
 1. WAX PATTERN MANUFACTURE
b/ Wax pattern making

WAXES USED

Present waxes – complex materials containing

following components:

- natural waxes TYPES of WAXES

- syntetic waxes
- natural resins - Straight (non-filled)
- syntetic resins - Filled (30% of filler)
- organic fillers - Emulsified
- water (by water, air)

Combination of different raw materials properties to achieve optimal wax characteristics:

-melting and congealing point
-hardness
-viscosity
-expansion/contraction
-solidification rate
- ash content (‹ 0,05%)
- flexibility
- surface quality
- stability to oxidation
- possibility to recycle
BASIC PRINCIPLE OF INJECTION MACHINE FOR WAX PATTERN MAKING

Wax storage
Valve

Sp (piston surface) Piston pump

Transport
wax hose vc

Injection nozzle
Piston

Injection cylinder
with wax

Master die
EQUIPMENT FOR WAX PATTERN MAKING –injection machine +wax melter + conditioner
 INJECTION CYCLE

Speed Pressure
controlled controlled τE …die cavity filling time
phase phase τK …packing time
τN …holding time
2 3
1000 τZ …cycle time
(till the die opening)
U (pre-set
packing
pressure)
Pressu NOTE:
re Points 1, 2, 3, 4 a 5 correspondent to the points in
[bar] following picture

Die opening
1a

1
4 5
1

τE τK τN
Time

τZ
 INJECTION CYCLE

1 bar 1 – 2 …pressure increase in die

Specif cavity → decrease of
ic 1
volum 200 spec.volume
[cm3/ 1a 2 – 3 …packing pressure →
g] 600 slight decrease of spec.volume
3 – 4 …pressure decrease during
1000
wax solidification → constant
4 2 spec. volume
3 1500 4 – 5 …wax cooling in die →
decrease of spec.volume
(contraction)

NOTE:
vSP = 1/ρ …specific volume [cm3/g]
ρ = 1/vSP …density [g/cm3]

TE (wax temperature during pattern TM (wax temperature during injection)

stripping from die)

Temperature [ºC]
EXAMPLES OF INJECTION MACHINES
WAX PREPARATION FOR INJECTION
EXAMPLES OF WAX PATTERNS
1. MANUFACTURE OF WAX PATTERNS
c/ Wax pattern assembly
Wax pattern assemblies
a) Horizontal placed patterns on a special
gating rings

Assembly Design Influenced by:

-Technique of pattern assembly (glueing/welding)

-Shelling technique

-De-waxing technology

-Pouring system
b) Patterns straight on gating sprue

-Casting cutting-off technique

-Standartization of gating systems

 2. MANUFACTURE OF CERAMIC SHELL
a/ Shell building and drying
I/ DEGREASING OF WAX PATTERNS
(removal of remaining separator from the wax pattern surface)
II/ DIPPING INTO CERAMIC SLURRY
(ceramic slurry consists of filler and binder)
Filler – heat resistant ceramic flour (fused silica,molochite,zircon,..)
Binder – colloidal silica sols based on alcohol (alcosols) or water (hydrosols)
III/ SHELL DRAINING

IV/ STUCCO APPLIED WITH CERAMIC GRIT

( fluid or rainfall systems)
Stucco materials – silica, molochite, alumina, zircon, atd.
Grain size according to the coat number :
- first 1-2 „prime coats“ fine particles –0,175-0,25 mm (CASTING SURFACE FINISH)
- next 3- x „back-up coats“ coarser – 0,25-0,5 mm (MOULD GAS PERMEABILITY)
V/ SHELL DRYING
(in aircondition room 2-4hours – temp. 20 °C ±1 °C , relative humidity 30-60%
-according to the type of binder used, sufficient air flow)
VI/ REPEATING ( II – V)
(till the needed number of coats – 8-12)
SLURRY MIXING TANKS
 SANDERS
Rainfall Fluidized bed
ROBOTIZIED SHELLING LINES
FULLY ROBOTIZED SHELLING LINE
 2. MANUFACTURE OF CERAMIC SHELL
b/ Shell de-waxing

KEY PROBLEM : different wax and shell expansion !

Wax expansion bigger,therefore danger of shell cracking during de-wax process.

NECCESITY of „dilatation gap“ building on wax pattern surface –

through THERMAL SHOCK – see picture bellow.

TECHNIQUES USED FOR DE_WAXING

I/ By overheated steam – in boilerclaves

II/ By firing – „flash fire“ system

CERAMIC III/ By microvave heating

SHELL
Thermal expansion

WAX
PATTERN
 2. MANUFACTURE OF CERAMIC SHELL
b/ Shell de-waxing

Majority foundries use boilerclave system

MAIN REASONS:
-Ideal steam properties for heat transfer
-Easy to collect de-waxed wax
-High efficiency

Typical working parameters:

-Steam temperature – 160-170°C
-Working pressure – 6-8 atm
-Reaching work.pressure in 4-5 s
-Controlled speed of pressure drop
DE-WAXING IN BOILERCLAVE
 WAX RECYCLING AFTER ITS DE-WAXING

WAX RECYCLING
REMOVAL OF IMPURITIES
+ NEW WAX ADDITION

BOILER
AUTOCLAVE TANK

16 hours

IMPURITIES

MASTER
STORAGE TANK DIE

GEAR PUMP
 2. MANUFACTURE OF CERAMIC SHELL
c/ Shell firing

GOAL: transfer of amorphous type of SiO2 binder layer into a crystallic one +
removal of volatiles matters (waxes remains)

1000
900 - 1080 ºC
900
60 – 80 min
≈ 5 ºC/min
800

700

575 ºC
600
Teplota [ ºC]

500 30 min

400
≈ 5 ºC/min

300

200

100 ºC
100
30 min
0
0 60 120 180 240 300 360

Čas [min]
DIFFERENT TYPES OF CERAMIC MOULDS MADE BY LOST WAX PROCESS
a) SOLID CERAMIC MOULD – COMPACT METHOD

CERAMIC SLURRY

a) SOLID CERAMIC MOULD – COMBINED METHOD

SLURRY SAND 2-3 SHELLS

(CEMENT)

c) BACKFILLED SHELL d) SELF SUPPORTING SHELL

2-3 SHELLS 5-8 SHELLS

POSSIBILITIES OF USING CERAMIC CORES

Ceramic core manufacturing:

-Preparation of ceramic mass

-Forming into a needed shape

-Heat treatment
 3. METAL POURING
GRAVITY UNDER VACUUM
a/ Classical pouring a/ Melting and gravity pouring under vacuum
b/ „Roll-over“pouring b/ Counter-gravity pouring (CLA , CLV)

GRAVITY POURING POURING UNDER VACUUM

VACUUM VACUUM

VACUUM
 POSSIBILITIES OF MOLTEN METAL FILTRATION

FILTRATION POSSIBILITIES

1.STRAINER CORES 3.EXTRUDED FILTERS

FILTER

2.FOAM FILTERS 4.GLASS FIBRES

FILTERS
4. FINISHING OPERATIONS

- casting cut-off from gating system

(by vibration , cutting )
- casting surface cleaning
(by blasting , grinding )
- casting heat treatment

5. CASTING QUALITY INSPECTION

- chemical composition, structure

(spectrometr, metalography )
- internal casting quality
(X-ray, ultrasonic )
- casting surface finish
(capillar methods )
- mechanical properties
(tensile strength, hardness, ductility, etc. )
- dimensional accuracy
E/ DIMENSIONAL ACCURACY OF INVESTMENT CASTINGS

INVESTMENT CASTING PROCESS

(Lost wax process) is

CASTING TECHNOLOGY where

A FINAL MACHINING SHOULD i.e. our goal is to achieve

BE ELIMINATED

NET – SHAPE CASTING to be ready for usage in

AS CAST CONDITIONS complying with all

DIMENSIONAL AND TOLERANCE

REQUIREMENTS
The average tolerance exhibited by various casting processes (by J.Campbell)
 THE FINAL CASTING’S
DIMENSIONS dependent on

Dimensional changes during individual stages of

investment casting technology

INVESTMENT
CASTING
PROCESS

FINAL
PATTERN CASTING
DIE DIMENSIONS
DIMENSIONS
 PATTERN DIE DIMENSION
must comply with

All subsequent dimensional changes during the process

i.e.
PATTERN MAKING

SHELLING

DE - WAXING

SHELL DRYING and FIRING

METAL POURING,
SOLIDIFICATION and COOLING
DIMENSIONAL CHANGES DURING INVESTMENT CASTING
PROCESS

tolerances
dimension 1 Tool cavity
ance s

2 Wax pattern
tole r

3 Dried shell
e ns ion +

4 Fired shell
D im

1 2
3
S ta 4 5 Final casting
g
p o e of 5
ces t
ss he
DIMENSIONAL ACCURACY OF INVESTMENT CASTINGS
F/ CAPABILITIES OF INVESTMENT CASTING TECHNOLOGY
 EXAMPLES OF CASTINGS MADE BY LOST WAX TECHNOLOGY
Aircraft engine blade – equiaxed structure, directional solidification,
single crystal - superalloys Ni base, vacuum cast

Superalloys Ni base, vacuum cast

-castings for power industry

Part of aircraft engine GE (Boeing 747,767) – Ti alloy

 EXAMPLES OF CASTINGS MADE BY LOST WAX TECHNOLOGY

Casing of tank control system – Al alloy

Part of helicopter V-22 – Ti alloy

Investment castings for shotgun-
Cr hardenable stainless steel
Boeing 777 APU duct- Ti alloy
EXAMPLES OF CASTINGS MADE BY LOST WAX TECHNOLOGY

Typical aluminium investment casting features

EXAMPLES OF CASTINGS MADE BY LOST WAX TECHNOLOGY

Investment vacuum castings for surgical implants ( knee and hip joints)
- Ti6Al4V alloys , CoCrMo alloys
 EXAMPLES OF
ALUMINIUM INVESTMENT CASTINGS

SUBSTITUTION OF ORIGINAL TECHNOLOGY USED

BY LOST WAX PROCESS
MACHINING+ WELDING INVESTMENT CASTING
+BENDING
Weight 0,5 kg Weight 0,2 kg
Material – Fe alloy Material – AlSi10 Mg
Dimensions 155x55x55 mm
Benefit – weight+ labour reduction, better part properties
 1. part PLAST-2.part Al Investment casting
machined by milling+ screwed
together
Weight 0,11 kg Weight 0,14 kg
Material: plast+ Al alloy Material AlSi10 Mg
dimensions 100x40x30 mm
Benefit – labour less demanding, increased lifetime and component utility
values
MACHINING -GLUEING INVESTMENT CASTING
Weight O,52 kg Weight 0,32 kg
Material – Al alloy Material: AlCu4 Ti
Dimensions 70x95x110 mm
Benefits: labour less demanding, increased component utility values
MACHINING,WELDING INVESTMENT CASTING
Weight 0,15 kg Weight 0,03 kg
Material – Fe alloy Material – AlSi10 Mg
Dimensions 40x40x40 mm
Benefits: by 30% less labour demanding, increased part utility value
MACHINING,BENDING, INVESTMENT CASTING
WELDING
Weight 0,05 kg Weight 0,02 kg
Material – Al alloy Material – AlSi10 Mg
Dimensions: 55x40x40 mm
Benefits: by 35% less labour , increased part utility value
PRESSURE DIE CASTING INVESTMENT CASTING
Weight 0,10 kg Weight 0,04 kg
Material : Zn alloy Material: AlSi10 Mg
Dimensions:60x60x25 mm
Savings: see next picture
 SAND CASTING INVESTMENT CASTING
Weight 0,25 kg Weight 0,20 kg
Material – AlSi10 Mg Material – AlSi10 Mg
Dimensions: 204x100x15 mm
Savings: less labour cost and increase of component quality
SAND CASTING INVESTMENT CASTING
Weight - 4,8 kg Weight – 0,8 kg
Material - grey iron Material - AlSi7 Mg
Dimensions 240x130x40mm
Benefit: Labour costs savings
 MACHINING INVESTMENT CASTING
Weight of piece for mach. 3,36 kg Weight 0,12 kg
Material – Fe alloy Material - AlSi10 Mg
Dimensions Ø 220x18 mm
Benefit: labour costs savings
 SAND CASTING INVESTMENT CASTING
Weight 2,4 kg Weight 1,8 kg
Material RR 350 ( AlCu5Ni) Material RR 350 (AlCu5Ni)
Dimensions: 150x150x110 mm
Benefits: weight reduction, increase of engine power by app. 15 %
 INVESTMENT CASTING AGAINST
PRESSURE DIE CASTING

• ECONOMICAL COMPARISON OF „CORNER“ CASTING

Inv.Cast. Press.Die IC(total) PD(total)

(CzCrowns) (CzCrowns)
Die price 30.000 460.000
1.000 pcs 45.000 16.000 75.000 476.000
10.000 pcs 450.000 160.000 480.000 620.000
15.000 pcs 675.000 240.000 705.000 700.000

BREAK-EVEN POINT IS app. 15.000 pcs

In other words only over this amount of castings is PD
technology more economical
AIRCRAFTS WITH „MIKRON“ ENGINES
(www.parmatechnik.cz)
 SAND CASTING INVESTMENT CASTING
Weight 8,7 kg (45 kg) Weight 2,7 kg
Material. Fe alloy Material:AlSi7 Mg T6
Dimensions: 260x260x100 mm
Savings: on material and labour
SAND CASTING INVESTMENT CASTING
Weight 0,9 kg Weight 0,4 kg

Material – Fe alloy Material AlSi7 Mg T6

Dimensions 150x80x60 mm
Benefit: weight reduction and less labour during machining
Customer:
Tadiran
Communications

Title:
Body 9004

Dimensions:
234 x 318 x 201 mm

Material:
A 356

Weight:
3,5 Kg
Customer:
BMT

Title:
Support

Dimensions:
190 x 301 x 240 mm

Material:
A 356

Weight:
1,33 Kg
Customer:
Borcad

Title:
Rack

Dimensions:
304 x 337 x 57 mm

Material:
A356

Weight:
0,82 Kg
Customer:
Uniplet

Title:
Cover

Dimensions:
209 x 360 x 118 mm

Material:
A356

Weight:
1,25 Kg
Customer: Title: Weight:
Wyman-Gordon Ramback side 1,38 Kg

Material:
Dimensions:
A 357
518 x 147 x 32 mm
THANK YOU FOR YOUR ATTENTION

HAVE A NICE DAY !