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INVESTING
CRUCIBLE FORMER
Attached to the sprue. Made of plastic, wax or ceramic material. Should be conical to allow rapid flow of the molten metal.
Investment Ring
Holds the investment in place during setting. Restricts the expansion of the mold.
Ring Liner
They fit into the casting ring without any overlap / gap. They can be used either wet or dry. In case that more expansion is to accommodated, two layers of the liner can be used. It can be made of ceramic, cellulose material or combination of both.
The liner should be 3.0 mm short of both ends of the ring. This will allow supporting contact of the investment with the ring after the cellulose liner has burned out. It is also theorized that this restriction near the open end will provide for more uniform expansion.
It use of Investments.
higher-strength,
phosphate-bonded
INVESTMENT MATERIALS
Requirements: 1. Sufficient strength to withstand burnout and casting. 2. Sufficiently porous to allow escape of gases. 3. Expand enough to compensate solidification shrinkage of alloy. 4. The ability to produce smooth castings with accurate surface reproduction without nodules. 5. Chemical stability at high casting temperatures. 6. Easy recovery of the casting.
Composition of Investment
Refractory material or filler Material that resist high temperature. Expand upon heating. Its problem have no cohesion to maintain the shape of investment when dried. Binder Mixed with filler to give some strength. holds other ingredients together and Provides rigidity. Chemical modifier
INVESTMENT MATERIALS
Gypsum bonded Low melting Gold alloys
The choice of the type of the investment used depends mainly on the melting range of the alloy.
Composition: Filler is silica quartz or cristobalite 60-65% provides thermal expansion when heated. Chemical modifiers. Gypsum Binder: Ca (SO4)2 (25-35%) decomposes at high temperature releasing sulphur contaminant produce rougher casting.
SHRINKAGE COMPENSATION
Solidification Shrinkage: Au alloys 1.5% Base-metal alloys 2.4%
Four mechanisms to produce mold expansion: 1. Setting Expansion 2. Hygroscopic Expansion 3. Wax Pattern Expansion 4. Thermal Expansion
1. Setting Expansion
Occurs as a result of normal gypsum crystal growth in air. About 0.4% but partly restricted by metal investment ring.
2. Hygroscopic Expansion
Max expansion: immerse investment-filled ring in water bath at 38C. 1. 2. 3. Water in bath replaces water used by hydration Process space between growing crystals is maintained. crystals grow longer . outward expansion of mold.
4.Thermal Expansion
Occurs when investment is heated in burnout oven.
Investment and metal ring expand enough to compensate for shrinkage of casting alloy.
Investing procedure
Investing procedure
The wax patter should be thoroughly cleaned.
Debubblizer (surface-wetting agent) is used to increase
the wettability of the wax surface, so to reduce entrapment of air bubbles on the surface during investing. Paint wax pattern with solution then dry with gentle air-stream.
A required amount of the liquid (distilled water for the gypsum based investment and colloidal silica for the phosphate based investments) is poured into a clean mixing bowl, to which the powder is added gradually.
Mixing should be done carefully to avoid creating any air bubbles in the wet mixture. The mixing can be done either manually, or mechanically under vacuum conditions. The latter method removes air bubbles from the mixture, and any other gasses that might be present.
Brush Technique
Vacuum Technique
Double investing
First step; the wax pattern is painted with
thick mix and is left till complete setting. -The set investment (first coat) is immersed in water for about 10 minutes.
Metal Casting
Metal shrinkage (~ 1.5-2%)
Its the elimination of the wax pattern from the mold of set investment material.
It: prepares mold for molten alloy. Allows thermal expansion to occur.
Burnout furnaces
Burnout techniques
Two burnout furnaces can be set at 200C and 650C or 480C, or a programmable two-stage furnace can serve equally well. However, the investment should not be overheated or kept at temperature too long. Gypsum-bonded investments are not stable above 650C. Also, some carbon in carbon-containing investments burns off, causing increased surface roughness of the casting.
Once the investment is heated during the wax-elimination procedure, heating must be continued, and casting must be completed. Cooling and reheating of the investment can cause casting inaccuracy because the refractory and binder will not revert to their original forms (hysteresis). Inadequate expansion and cracking of the investment are typical results.
Burnout Requirements
Temperature rate of rise for the burnout furnace is 10*C/min. It is advisable to begin the burnout procedure while the mould is still wet because: Water trapped in the pores of the investment reduces the absorption of wax so when the water vaporizes it flushes wax from the mold.
Temperature Soak:
The temperature to which the casting ring is heated must be sufficiently high.
This temperature should be maintained long enough (45min.) to avoid sudden drop in temperature upon removal of the ring from the burn-out furnace. This drop in the temperature can lead to incomplete casting as a result of rapid solidification of the alloy as it enters the mold cavity.
Technique
Allow invest. to set & then remove rubber crucible & metal sprue.
Remove smooth skin that forms on the ring with phosphate bonded investment. Place the ring with the sprue facing down in the furnace on a ribbed tray. The tray allows the molten wax to flow out freely.
Increase temperature in furnace up to 200C for 30 min. Increase heat to the final [ 480C or 650C ] for 45 min.
The rate at which the investment is heated is a factor in producing a smooth surface casting. Rapid heating will result in evaporation of the water of the investment forming steam that cause cracking with a rough surface and fins.