Madras Engineering Industries Pvt Ltd.

, Chennai

Training Program on Casting Process

Madras Engineering Industries Pvt Ltd., Chennai

Let us discuss the manufacturing process for above part

Madras Engineering Industries Pvt Ltd., Chennai

Let us discuss the manufacturing process for above part

Madras Engineering Industries Pvt Ltd., Chennai

Let us discuss the manufacturing process for above part

Madras Engineering Industries Pvt Ltd., Chennai

INVESTMENT CASTING

Investment Casting
Investment Casting, often called lost wax casting, is regarded as a precision casting process to fabricate near-net shaped metal parts poured from almost any alloy including: stainless steel, carbon, steel, aluminum, brass, bronze and copper.

Investment Casting
Ferrous investment casting are castings that cast stainless steel, including 300/400 series alloys and any precipitation hardened steel alloys, as well as non-ferrous investment castings (copper based alloys, zinc based alloys, aluminum, bronze & iron).

Investment Casting
Casting by the investment process allows for parts to meet x-ray and non destructive testing specifications for: military, aerospace, semi conductor industry, valves, pumps and many other industrial applications.

Investment Casting
The investment casting process consistently provides high integrity (sound) and dimensionally accurate castings. Cast part dimensions vary less than +/- .001 from part to part.

Investment Casting
Investment casting uses a mold that has been produced by surrounding an expendable pattern with a refractory slurry that sets at room temperature. The pattern (usually of wax or plastic) is then melted or burned out, leaving the mold cavity. Investment casting is also known as the "lost wax process" and as "precision casting".

Process Flow

Wax Injection
The investment casting process begins with production of a heat disposable pattern. This pattern is usually made by injecting molten wax or plastic into a metal die or mold.

Pattern Assembly
The wax patterns are attached by the gate to a central wax runner system. The runner system is called a sprue. Patterns, runners, and pouring cup compromise the cluster or tree.

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Shell Building
The shell building technique involves dipping the assembly into a ceramic slurry and then into a bed of extremely fine sand. After drying, the process is repeated. Up to 7 layers may be applied in this manner.

Dewax Operation The completed

shell is placed in a steam autoclave where the wax pattern melts and runs out through the gates and pouring cup.

Firing the shell mould

Molds are placed into a kiln at 2000, this cures and hardens the investment casting mold

Casting
Molds are removed from the kiln while the mold is still hot to reduce thermo shock, metal is then poured directly into sprue cup.

Knockout
Once molds have cooled for approximately one hour the ceramic shell is knocked off from the metal investment castings and runner system.

Cut Off & Cleaning

Castings are cut from the sprue tree.

Benefits of Investment Castings

1. The Investment Casting process is capable of making parts from prototypes to high volume. 2. Investment Casting tooling is capable of making over 1 million parts per tool. 3. Cast tolerance to +/- .005 or better, per inch. 4. Cast surface finish of 125 RMS or better. 5. Excellent cast details with regards to cast letter i.e. logo, names, part number, etc. 6. Reduced machining due to castings designed to near net shape. Investment castings can have undercuts, blind holes, thru holes 0.25mm or greater and, almost any geometric shape or size.

All of the above advantages reduce your casting costs.

Demonstration

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