Advances in investment casting over the past several years have enabled cost reductions and improved reliability

in complex components. Michael C. Perry

Executive Director Investment Casting Institute Montvale, New Jersey

INVESTMENT CASTING

ngineers are finding ways to bypass timeconsuming and expensive production routes by investment casting hundreds of parts that were never cast before. Technological progress has improved control at every stage of the process, spurred alloy development, effectively exploited the considerable design freedom of the process, and leveraged the unique features of investment casting to enhance capability, repeatability, and affordability. Foundries have steadily reduced variability through the application of microprocessor controls, automated equipment, statistical methods, and scientific management techniques. For example, early attempts to cast jet-engine airfoils with hollow cores, cast-in cooling schemes, and thin walls, often produced unacceptably low yields. However, airfoils now in production are characterized by directionally solidified and single-crystal designs, ultra-thin walls, and internal coring, with yields over 90%. Large, complex structural parts made of aluminum and titanium are cast with comparably high yields. Similar or better outcomes are achieved for parts in a wide variety of other high-tech industrial applications. In fact, the multi-step investment casting process (see sidebar) now results in predictable manufacturing and high yields.

Fig. 1 The motorcycle exhaust transition above is manufactured by MCM Precision Castings Inc., Weston, Ohio.

Alloy selection was simplified. The OEM wanted an alloy that was not commonly cast to make the exhaust transition, because of its commonality with adjacent parts and for its reliability. Testing demonstrated that the alloy could be successfully cast for this application, thus enabling the redesigned component to be manufactured with the same material as adjacent components. The amount of material was reduced. The redesigned component, which features minimal gating, now delivers the double benefit of reducing raw material input requirements (in this case 429 stainless steel) and minimizing interference in postcasting plating and polishing steps. Manufacturing cycle time and expenses were significantly reduced because the three detail parts previously used to make the exhaust transition had to be stamped, formed, and welded. However, when produced as a single-piece casting, all of these operations were eliminated. Conversion of a hog-out This fork roller (Fig. 2), a key component of an oil-drilling pump, is an example of the relatively large components (18 x 16 x 2 0 inches) that can be investment cast. In this case, the pump manufacturer wanted to remove unnecessary weight and reduce manufacturing expense, while still maintaining the ruggedness of the finished component. The previous fork roller, which started out as 740 pounds of 15-5 PH steel and ended up as a 260pound forging, was hogged out of a steel block almost three times its size. By converting this component to a casting, engineers produced a near-net shape that dramatically 31

Converting from a fabrication An examination of one relatively small automotive casting quickly illustrates the advantages of switching from a fabricated assembly to a casting. Originally made from three detail parts, the motorcycle exhaust transition shown in Fig. 1 is produced in two sizes, the smallest of which is 4.5 x 5 x 2.5 inches. This part provided the following benefits when converted to a casting: Product performance was enhanced in the areas of exhaust gas flow and horsepower rating. During the conversion from a fabrication to a casting, the component was redesigned to eliminate the welds and seams in the gas path that had previously obstructed the flow of exhaust gas.

ADVANCED MATERIALS & PROCESSES/JUNE 2008

Fig. 2 Destined for application in an Fig. 3 Vestshell Inc. of Montreal, Canada, oil-drilling pump, this fork roller is made by produces the pre-cooler shown here for an Tech Cast Inc., Myerstown, Pa. aircraft engine vent.

Fig. 4 A component of a vertical conveyor, this clamp is made by Becker Metal Works, located in St. Clair, Mich.

reduced machining requirements while also greatly improving raw material utilization and work-inprocess expenses. The cast fork roller is not only lighter than the 260-pound hog out it replaced, but cost about 39% less to manufacture. Complex geometries Investment cast complex geometries provide a ripple effect of subsequent benefits. A pre-cooler for an aircraft engine vent (Fig. 3) is an example of a casting that presented a number of engineering challenges. Requirements included a high-temperature operating environment, complex part configuration, and restricted fit-up space. The design team ultimately decided to specify a 410 stainless steel component, produced via the investment casting process. They concluded that this route would best produce a part with the dimensional stability, precise geometry, and ruggedness needed for the harsh operating environment of a jet engine.

In addition to meeting performance goals, investment casting helped streamline the production process through part-count reductions and the elimination of multiple finishing, assembly, and inspection requirements. Rapid solutions An equipment manufacturer needed a vertical conveyor clamp (Fig. 4) and needed it quickly. Previously machined out of bar stock, the two-piece assembly consumed an excessive amount of raw material, as well as machining and assembly time, precluding delivery within the eight-week time frame. However, when redesigned as a single-piece,

Investment Casting Process

The investment casting, or lost-wax process is a production method for making parts from molten metal. The process begins with the manufacture of a pattern that is the same shape as the end product. Usually made of wax formed in custom tooling, the individual pattern elements are joined to form a wax-pattern assembly. The assembly is repeatedly dipped into a ceramic slurry and coated with sand stucco to build up a shell, which is then dried. When the shell is dry, the assembly is placed in an autoclave and the wax is melted out. When empty, the mold is heated to the proper temperature and molten metal is poured into the mold. As the metal cools, it solidifies into a casting. Subsequently, the mold is broken off and the casting undergoes a number of finishing operations.

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12 x 18 x 2.5 inch, carbon-steel clamp, the time and cost savings were significant. The caster was able to process the order, design the piece and tooling, take delivery of the tooling and raw material, and produce 400 parts in six weeks, in 25% less time than planned. Supporting technologies Advances in wax formulation and wax injection at the pattern-making stage have opened the door to new process capabilities. The selection of wax, which is used for making the patterns that are dimensional representations of cast parts, has an impact on all subsequent steps in the process. For example, a foundry that wants to reduce or eliminate machining, can tighten near-net-shape tolerances and improve the quality of surface finishes by selecting the most appropriate wax. Companies that supply wax injection equipment to casters have demonstrated that automating the wax-pattern assembly step has a positive effect on manufacturing cycle time, net-shape accuracy, and process repeatability. Equipment suppliers that have developed high-speed drying technology have shown how shell-building time can be reduced from days to hours. Vacuum-furnace manufacturers have made comparable advances, as have raw material suppliers, manufacturers of inspection instruments, and suppliers of finishing equipment. The end result is the ability to cast larger, more complex components,

The Investment Casting Institute will host the 12th World Conference in Dallas, October 19-22, 2008. The event, held every four years, is sponsored jointly by the Investment Casting Institute (US), the Cast Metals Federation (UK), and the European Investment Casting Federation. The conference provides a global forum for participants in the investment casting industry to network with international peers, attend technical presentations, and visit exhibits of new equipment, products and services. It has been 12 years since the World Conference was last held in the United States. www.investmentcasting.org with higher process yields, in shorter time frames than possible in previous years.
For more information: Michael Perry, Investment Casting Institute, 136 Summit Avenue, Montvale, NJ 07645-1720 ; tel: 201/573-9770; www.investmentcasting.org.

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