Complexity in one go

The manufacturing technology of investment casting is an ideal choice for complex parts and can minimize the need for complicated machining. The advantage of this process is that it delivers castings normally ready for assembly and requiring very little finishing.  

Investment casting is a method of producing castings in the lost-wax process. The resulting parts stand out for their high level of detail, dimensional accuracy and surface quality. In many cases, the technology can eliminate the need for machining.

The process is used for castings with a typical mass of 30 g to 200 kg. Higher part weights are possible. The technology is suitable for the casting of virtually any steel and alloys based on iron, aluminum, nickel, cobalt, titanium, copper, magnesium or zirconium.

The castings are normally ready for assembly or require only very little machining. As a rule of thumb for efficiency, investment casting is particularly attractive for components of complex geometry and/or eliminating the need for complicated machining. Further benefits can be derived by integrating fixtures into the part for subsequent manufacturing steps. Investment casting is an especially profitable process for larger volumes.

The process

Modeling

For each component, a wax model is made by injection molding.

Cluster assembly

Several wax models and the sprue, also made of wax, are combined to a casting cluster.

Ceramic mold manufacture

The mold is created by dipping the model into ceramic slurry, followed by sanding and drying. These steps are repeated several times until the desired strength of the shell is achieved.

Dewaxing and baking the mold

The wax is melted out of the models, and the ceramic molds are fired.

Melting and casting

The desired alloy is poured into the preheated molds.

Mold removal and degating

Once the alloy has solidified, the ceramic mold is removed and the sprue is separated from the castings.

Heat treatment and finishing

The parts can then be heat treated and reworked, if required.

Quality control

The parts are checked for compliance with drawing specifications and material properties.

Investment castings

Manifold

  • Size: 68 x 85 mm
  • Weight: 170 g
  • Material: 1.4301

Cam

  • Size: 105 x 36 mm
  • Weight: 93 g
  • Material: 41 CrMo 4

Twine holder

  • Size: 66 x 67 mm
  • Weight: 350 g
  • Material: 41 CrMo 4

Housing

  • Size: 50 x 65 mm
  • Weight: 122 g

Gear controller

  • Size: 113 x 45 mm
  • Weight: 287 g

Flange

  • Size: 88 x 80 mm
  • Weight: 112 g
  • Material: G 1.4828

Almost any metal material can be processed by investment casting. The technology is particularly suitable for alloys difficult to machine.

Benefilts

  • complex geometries
  • little/zero rework
  • high surface quality
  • hohe Maßgenauigkeit
  • broad material choice

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