Production process

In the manufacturing industry, investment casting (also known as lost-wax casting) is a critical process for aerospace, medical, and automotive applications due to its high precision, complex geometry capability, and excellent surface finish. As a professional investment casting foundry, we maintain strict control over each step from raw material to final product. This article details the complete production workflow of precision casting.

1. Pattern Die Design & Manufacturing: The "Blueprint"

Using CAD/CAM 3D modeling and rapid prototyping (3D printed silicone molds or CNC machined metal dies), we create dies with±0.05mm to ensure wax pattern accuracy.

Key Techniques:

• Reverse engineering for part replication

• Mold flow analysis for optimal metal filling

2. Wax Pattern Production & Assembly

Special casting wax is injected into dies under controlled temperature (60-80°C). Patterns are inspected via CMM (Coordinate Measuring Machine) and assembled manually for complex parts.

Quality Control:

• Wax shrinkage compensation (0.8-1.2%)

• Surface finish Ra≤1.6μm

3. Shell Building: Creating the Ceramic Mold

Multi-layer ceramic shell construction:

1. Prime coat: Zircon flour + colloidal silica

2. Backup coats: Mullite sand + alumina silicate

3. Drying: Controlled humidity environment

Parameters:

• Shell thickness: 5-12mm

• Typical layers: 6-9

4. Dewaxing & Firing: Mold Preparation

High-pressure steam autoclave dewaxing (15-30 mins) followed by high-temperature firing (900-1100°C) to remove residual wax and strengthen molds.

5. Metal Melting & Pouring

Alloys (stainless steel/aluminum/titanium) are melted in vacuum induction furnaces with precise pouring temperatures (e.g., 316L at 1500-1600°C).

Advanced Methods:

• Directional solidification

• Vacuum-assisted casting

6. Post-Casting Processing

1. Shell removal: Vibratory cleaning + sand blasting

2. Cutting: Band saw/laser cutting of gates

3. Heat treatment: Solution annealing, etc.

4. Machining: CNC milling/grinding

7. Quality Assurance

• Dimensional inspection: CMM (CT8 tolerance)

• NDT: X-ray, fluorescent penetrant testing

• Material analysis: Spectrometer verification

Why Choose Investment Casting?

✔ Complex thin-wall parts (min. 0.5mm thickness)
✔ CT4-CT8 dimensional accuracy
✔ 95% material utilization rate

Conclusion
This engineered process combines craftsmanship with metallurgical science, ideal for high-specification components. Contact us for custom casting solutions.

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