Investment Casting Process Steps at PT SPV Majubersama Casting Company

At PT Stainless Steel Primavalve Majubersama Company, we have many years of experience in the investment casting industry. We produce investment castings from both ferrous and non-ferrous metals in the required specifications

Investment casting, which is also known as the "lost wax investment casting" process, traces its roots to the Sang Dynasty in China from 1776 B.C. to 112 B.C. The method was brought into modern industrial use when American manufacturers applied investment casting to make high quality military parts during World War II. It was found practical for many wartime needs - and during the postwar period it expanded into many non-aircraft applications. Today, investment casting is recognized and used worldwide as a technique for producing close-tolerance metal parts at highly competitive costs.

We lead the competition in quality, value, delivery and service. Our Quality Management Standard (DIN EN ISO 9001 : 2008) assures customers of our commitment to quality in both product and service. As for customer satisfaction, it is achieved by the application of effective management and by a continuing programme of capital investment, which is shown in our recently opened new factory. We strive to build that satisfaction into long-term relationships.

The following steps are what we follow to produce parts with complex geometries and intricate details.

1. Create wax pattern: A pattern that replicates the finished part geometry is made using one of two primary methods:
2. Wax Assembly: Next, the wax patterns are assembled onto runners and into a finished tree which is ready to be dipped.
3. Slurry Coating: The assembly is then dipped into a high-grade ceramic slurry to build a ceramic shell around the wax tree.
4. Stuccoing: After the slurry coating is done, particles of sand are dropped onto the surface of the wet tree assembly. This helps to thicken and strengthen the layer of coating on the wax assembly surfaced
5. Repeat Steps 5 and 6: Repeat steps 5 and 6 until the assembly achieves the desired shell thickness. The assembly is then allowed to set and dry.
6. Dewaxing: The wax inside the newly built shell is now removed. Dewaxing is done using a steam-dewaxing autoclave or flash fire furnace.
7. Casting: Now the desired molten metal is poured into the pre-heated mold cavity.
8. Cooling: The mold then sits to allow the molten metal to cool and solidify which then becomes the final casting.
9. Shell Removal: The shell material is then removed through processes hammer knockout, vibration, and steel grit blasting.
10. Cut Off: The finished parts are then cut free from the gating and runner system.
11. Finishing: Various finishing techniques are then employed including grinding, sand blasting and coating to achieve the final surface needed.
12. Testing: Once the finishing operations are done, the parts are inspected for surface and sub-surface defects. Visual and fluorescent penetrant inspection is done for surfaces and X-ray is employed for sub-surface defect identification.

                                                             Schematic illustration of Investment casting 

Applications:

We are proud to produce complex investment cast parts with superior surface finishes in the industries fastest lead-times for the following markets:

• Defense
• Powerplant
• Electronics
• Automotive / Transportation
• Marine
• Oil and Gas
• Agriculture
• Commercial

Advantages of Investment casting Technology

• Parts with extremely complex shapes and intricate features can be cast as a single piece using investment casting
• With short length or shallow depth feature, thin sections down to 0.40 mm (0.015 in) can be cast without cold shut defects
• Lost wax casting has excellent dimensional accuracy and tighter tolerances of 0.075 mm (0.003 in) are easily achievable.
• Compared to similar manufacturing processes, Investment casting can achieve an excellent surface finish without any post-processing. Typically around 1.3 – 0.4 microns RMS Ra
• It offers almost unlimited freedom in terms of investment cast materials, but the most common materials used include Aluminium alloy, cast iron and non-ferrous alloys. The process is particularly attractive for high-temperature alloys.
• Draft on walls are not required but if a master die is used to make wax patterns then draft on the face would help the pattern making process easier.
• Since there are no parting lines, the cast would not have any flash. But the wax patterns might have parting lines from the master die.
• Additional machining can be eliminated or reduced and an allowance of as little as 0.4 to 1 mm (0.015 to 0.040 in.) is usually enough.
• Excellent dimensional precision can be achieved in combination with very smooth as-cast surfaces. These capabilities are especially attractive when making products from the high-melting temperature, difficult-to-machine metals that cannot be cast with plaster- or metal mould processes.
• The wax used can usually be recovered for reuse.

Why investment casting and why SPV

1.  Allows greater design freedom for very simpleto highly complex parts

2.  Provides superior repeatability

3.  Can utilize a wide variety of alloys.

4. Yields lighter , stronger metal parts with superior finishes.

5.  Reduces labor, tooling and machining costs.

6.  Allows very rapid prototype development.

We are manufacturing the Excellent Parts through precision casting technology, high precision machining machines, measuring and laboratory equipments, to provide high quality parts for worldwide industry with supported by  

• The Highest Level of Quality.

• Great Lead Time for New Produt Launches

• Focus on Steel and Ferrous Metal.

• All in House Production.

• Advanced Technology Applied in Processes

• High Quality /Experienced People.

for more info and inquiry please contact us :

Viona Angelin

Sales Manager Casting Division

Email      : [email protected]

Call / Whatsapp : +62 811-1909-1900

www.spvmb.com