Beruflich Dokumente
Kultur Dokumente
Wax pattern
Gating system
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
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
WAXES USED
Wax storage
Valve
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
NOTE:
vSP = 1/ρ …specific volume [cm3/g]
ρ = 1/vSP …density [g/cm3]
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
-Shelling technique
-De-waxing technology
-Pouring system
b) Patterns straight on gating sprue
WAX
PATTERN
2. MANUFACTURE OF CERAMIC SHELL
b/ Shell 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
-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)
VACUUM VACUUM
VACUUM
POSSIBILITIES OF MOLTEN METAL FILTRATION
FILTRATION POSSIBILITIES
FILTER
INVESTMENT
CASTING
PROCESS
FINAL
PATTERN CASTING
DIE DIMENSIONS
DIMENSIONS
PATTERN DIE DIMENSION
must comply with
SHELLING
DE - WAXING
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
Investment vacuum castings for surgical implants ( knee and hip joints)
- Ti6Al4V alloys , CoCrMo alloys
EXAMPLES OF
ALUMINIUM INVESTMENT CASTINGS
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