At MetalCast we specialize in the industrial manufacturing of metal parts using the precision casting or investment casting process
The process of lost wax casting began in ancient China and Egypt to create art. It was generally used to produce art until the development of the jet turbine in World War II. Since that time it has become a technology developer in today's industries.
Some of its benefits or applications are:
- Aerospace
- Electric Generation
- Automotive
- Oil and Gas
- Space exploration
- Medical and Orthopedic
- Agriculture
- Construction
BENEFITS
- Superior surface finish
- Wide range of alloys
- Complex geometries
- Fine details
LEARN ABOUT OUR PROCESSES
1. CREATING THE WAX PATTERN
In today's manufacturing, wax patterns are usually created by injecting wax into a tooling. Although it is worth noting that with today's technology the wax pattern can be printed.
2. TREE ASSEMBLY
Logical sense tells us that it is unprofitable to create small parts one at a time, so the wax patterns are added to a wax pot. Which has two functions
Provide a surface for the patterns to come out in one mold.
Create a path through which the molten alloy will pass
The wax between the pot and the pieces is called casting, which is the feed and the part that gives the direction to the flow of the alloy.
3. CERAMIC MOLD CONSTRUCTION
The next step in the process is to create a ceramic shell around the tree in wax, this shell will eventually become whatever contains the molten metal. For the construction of this the tree is immersed in a ceramic bath or mud, then fine layers of sand or stucco are applied to the wet surface. The process is repeated a number of times until the ceramic mold is able to withstand the stress of the casting process.
4. WAXING AND BURNING
Before the metal is poured, the wax is removed, this is typically done in an autoclave using steam pressure, which is like an industrial pressure cooker. Another method is to use an oven that melts the wax. Many foundries use both methods. The autoclave removes most of the wax, which can be recovered, and the oven burns off the residual wax and sinters the shell, making it ready for the melting process.
5. METAL POURING
- Before the metal is poured into the ceramic mold, the mold is preheated to a certain temperature to prevent thermal shocks, and not completely filled with cold metal
- The alloy is melted into a ceramic cup called a crucible, using the induction melting process.
- A high electrical frequency creates a magnetic field around the alloy, generating electrical fields inside the metal.
- Currents heat the alloy due to the electrical resistance of the material.
- When the alloy reaches the specified temperature, it is poured into the mold, and the mold is allowed to cool.
6. REMOVAL OF THE CERAMICS
Once cold, the shell is removed from the metal. This typically happens by mechanical means:
- Hammer
- Vibration table
- High pressure water shots.
The removal of the ceramic shell can also be accompanied chemically, using a hot soda solution or also potassium hydroxide or sodium hydroxide.
7. CUT
Once the shell is removed, the parts are cut from the pot, and the castings are removed.
Parts can be cut manually:
- Saw
- Laser
- Arc air
Parts can also be cut automatically by an automated saw.
8. INDIVIDUAL CASTINGS
Once the parts are removed from the pot, and the castings are removed, the surface can be finished in several ways.
- Vibrational
- Manual grindings
- Polished
The finishing can be manual, but in many cases it is automated.
The pieces are then inspected, marked, if required packed, and shipped.
Depending on the application, the parts can be used in their net form, or be machined for greater precision.
Contact our team to identify the necessary elements so that your project of production of metallic pieces to the measure has the characteristics that this looking for your company.
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