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Metal casting has been dated back to the Neolithic period ( 6000 – 1800
B.C).
In starting stage castings were made in order to create necessary tools
and weapons.
Today casting technique plays a major role in industries
Classification of Casting process
Sand Casting
Permanent
pattern casting
Plaster
Casting
Expandable
mold casting
Investment
casting
Temporary
pattern casting
Lost foam
casting
Permanent mold Casting processes
In this method of casting the mold used for casting is permanent, i.e. mold
can be used repeatedly
In this method mold can be made of metals,ceramics etc..
Gravity Die
casting
Permanent Centrifugal
mold casting casting
Pressure Die
casting
Sand Casting
Investment casting is the process in which the wax pattern is coated with
refractory ceramic material. Once the ceramic material get hardened its
internal geometry takes the shape of the casting.
After the wax melted out and the molten metal is poured in to the shell or
mold.
Investment casting is also known as Lost wax casting.
Why it is called as Investment casting
or Lost wax casting
Steps in Investment Casting
Pattern injection
Pattern assembly
Primary coating
Backup coating
Final seal dip
Dewaxing
Shell sintering
Melting
Steps in investment casting
Pouring
Knockout
Runner and gate cutting
Grinding
Heat treatment
Blasting
Pickling and passivation (Only for stainless steel)
Inspection
Pattern injection process
This is 1st ceramic coating in the pattern tree assembly using refractory
flour and sand.
The below materials is needed for primary coating process
1. Zircon flour
2. Zircon sand
3. Binder
4. Antifoaming agent
5. Wetting agent
Steps in primary coating
At 1st liquid slurry is prepared using mixing of zircon flour, binder, anti-
foaming agent, wetting agent.
After the slurry got ready, pattern tree assembly is dipped in the slurry
Then the pattern tree assembly coated with zircon sand
Then the shells should be kept dry for specified drying time.
Back-up Coating Process
Before start backup coating ensure that the primary coated shells are
dried properly or not. If not dried keep some more to dry, then move to
next Process
At 1st liquid slurry is prepared using mixing of Silimanite flour, binder, anti-
foaming agent.
After the slurry got ready shells are dipped in to the backup slurry.
Then shells are coated with refractory sand
Backup coating consist of minimum more than two backup coats
Each back up coat slurry ceramic flour and sand material are same, but
the mesh size of the sand only vary.
Final coating or Seal Dip
Final coating is the final step of shelling process in which seal the shell
using refractory ceramic slurry.
Slurry material is same as Backup coating slurry.
No refractory sand is used for seal dip
After seal dip shell should allowed to dry,
Steps to Take care in shelling
Dewaxing is the process in which wax from the ceramic shell is melted out
using autoclave and boiler
After the shells got dewaxed , wax should be taken out and should be
recycled for use,
Shell sintering process
After the metal get solidified the ceramic materials are knocked out using
vibrator
Ceramic material cannot be reusable
Runner and Gate Cutting