Investment Casting Services
Investment casting, also known as lost-wax casting, is a best and precise method of forming metal parts. This process is perfect for creating complex and detailed components that are hard to achieve with other manufacturing methods. Investment casting works with a variety of materials, including stainless steel, carbon steel, aluminium, and brass. It provides a smooth surface finish, tight tolerances, and reduces the need for additional post-processing, saving both time and cost.
Over the years, we have developed strong expertise in investment casting, making us a trusted partner for clients around the world. With our experienced team, advanced facilities, and modern technology, we provide top-quality castings for industries such as aerospace, automotive, medical, and more. We offer a full range of investment casting services, from design assistance and rapid prototyping to production, ensuring you get exactly what you need. Investment casting, also known as lost-wax casting, is a process used to make detailed metal parts. It’s especially good for creating parts with complex shapes and fine details that are hard to make using other methods.
Our Investment Castig Process
Investment casting, also known as lost-wax casting, is a precision manufacturing process used to create complex metal components. The process begins with creating a wax pattern that replicates the final metal part. This wax model is then assembled onto a sprue to form a tree-like structure if multiple parts are cast together. The assembled patterns are dipped into a ceramic slurry and coated with fine sand multiple times to build a strong ceramic shell. Once the shell hardens, the wax is melted out, leaving a hollow mold. The mold is then heated to remove any remaining wax residue and strengthen the ceramic. Molten metal is poured into the heated mold, filling the cavity left by the wax. After the metal solidifies, the ceramic shell is broken away, revealing the cast part. The final step involves cutting, finishing, and machining the casting as required, ensuring it meets precise specifications. Investment casting is widely used for producing high-precision components in industries such as aerospace, automotive, and medical.
Pattern Creation
Pattern creation in investment casting involves making a wax replica of the final metal component using a precision-machined metal die. Molten wax is injected into the die, cooled, and carefully removed. Multiple patterns can be assembled into a tree-like structure for efficient casting. To ensure accuracy and defect-free results, the wax patterns must be high-quality, as any flaws will be replicated in the final metal part.
Mold Making
Mold making in investment casting involves coating the wax pattern with multiple layers of ceramic slurry and sand to create a strong shell. After drying and hardening, the wax is melted out, leaving a hollow ceramic mold. The mold is then fired at high temperatures to remove any wax residue and enhance its strength, preparing it for metal pouring.
Wax Removal
Wax removal in investment casting involves heating the ceramic mold to melt and drain the wax, usually using an autoclave or furnace. Any remaining wax is burned off to ensure a clean cavity. This process prevents defects and strengthens the mold, preparing it for metal pouring.
Metal Pouring
Metal pouring in investment casting involves heating the ceramic mold and filling it with molten metal. The metal is melted to the required temperature and poured carefully to ensure a complete fill. Techniques like vacuum or centrifugal casting may be used to enhance quality. Once poured, the metal solidifies, forming the final shape of the casting.
Shell Removal
Shell removal in investment casting involves breaking the ceramic mold using mechanical or chemical methods to reveal the metal casting. The casting is then cleaned to remove any remaining ceramic residue, ensuring a detailed and high-quality surface finish.
Finishing
The finishing process in investment casting involves cutting the casting from the gating system, removing excess material, and cleaning the surface. Machining and heat treatment may be applied for precision and strength. Quality inspections ensure the final product meets specifications before use.
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Post-Production Machining and Finishing Process
The Post-Production process in investment casting includes additional treatments and quality checks to ensure the casting meets final requirements. After finishing, the casting may undergo heat treatment to improve mechanical properties like strength and hardness. Surface treatments such as polishing, plating, painting, or coating can enhance corrosion resistance and appearance. Machining operations like drilling, milling, or turning refine dimensions and tolerances as needed. Non-destructive testing (NDT) methods, such as X-ray inspection, ultrasonic testing, or dye penetrant testing, help detect internal or surface defects. Finally, dimensional inspection ensures the part meets exact specifications before it is approved for assembly or shipment. These steps enhance the casting’s durability, precision, and performance for its intended application.
Heat Treatment
Heat treatment improves the strength, hardness, and durability of the casting by modifying its internal structure. The type of heat treatment depends on the material used and the desired properties. Some common heat treatment processes include:
- Annealing: Reduces internal stress and improves ductility.
- Normalizing: Refines the grain structure and enhances strength.
- Quenching & Tempering: Increases hardness and toughness.
- Solution Treatment & Aging: Common for aluminum and stainless steel to enhance corrosion resistance and mechanical strength.
Surface Treatments & Coatings
To improve the appearance, corrosion resistance, and wear properties of the casting, various surface treatments are applied, such as:
- Sandblasting / Shot Blasting: Removes residual ceramic shell and smoothens the surface.
- Electropolishing: Used for stainless steel to achieve a mirror-like finish.
- Plating (Nickel, Chrome, Zinc): Adds a protective coating against corrosion and wear.
- Powder Coating / Painting: Provides additional surface protection and aesthetic appeal.
Precision Machining
Some castings require tight tolerances or specific geometries that cannot be achieved during casting alone. Machining is performed using techniques like:
- Milling: Creates flat surfaces and precise features.
- Turning: Used for cylindrical parts.
- Drilling & Tapping: Adds holes or threads for assembly purposes.
- Grinding & Lapping: Achieves a high surface finish and tight tolerances.
Non-Destructive Testing (NDT) & Inspection
To ensure the casting is free from internal or surface defects, quality inspections are conducted using various non-destructive testing (NDT) methods:
- X-ray Radiography: Detects internal porosity, cracks, and inclusions.
- Ultrasonic Testing: Checks for internal defects using sound waves.
- Magnetic Particle Testing (MT): Identifies surface cracks in ferrous metals.
- Dye Penetrant Testing (PT): Highlights surface defects and cracks in non-ferrous metals.
- Dimensional Inspection: Uses Coordinate Measuring Machines (CMM) to verify precise measurements.
Final Processing
If the casting is part of a larger product, assembly operations such as welding, fastening, or joining may be required. Additional final processes include:
- Deburring & Edge Finishing: Ensures smooth edges for safe handling.
- Marking & Engraving: Adds serial numbers, company logos, or part details for traceability.