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Process Design Design the tooling according to customs’ drawing or sample, set up the pouring system with CAE casting simulation software. Mould Fabrication Transfer the drawing or sample into 3D drawing which is applied to aluminum or steel mould fabrication. Wax Injection Mix liquid wax slurry and solid wax together, inject wax into metal mould, fetch it out after cooling. Wax Mold Assembly Heat the stainless steel welding knife, weld the wax molds together on the gate stick according to technically designed. Dipping The wax molds are dipped into water glass solution, with surface coated by the solution. Stuccoing Stucco the dipped wax molds with quartz sand, then dip into induration solution containing ammonium chloride & magnesium chloride and hang to dry. The whole process repeats 6 times. Wax Removal Put the thick coated wax molds into wax removal gutter, keep heating. After lost all the wax only sand shell was left. Sand Shell Preheat Heat the sand shell in order to strengthen the shell. Casting Put the raw material into the induction furnace and melt, add with chemical composition per material spec. After the temperature of molten steel rises to about 1600 degrees, take a pre-pouring chemical analysis, if approved then pour liquid steel into the sand shell by ladle, make sure the shell is filled with liquid steel and then cool off, meanwhile take the testing bar for after-pouring analysis. Sand Shell Removal Make the casting free from sand by shaking. Cutting Oxyacetylene cut off the castings from gate stick. Grinding Grind the ingate and defected surface with grinding wheel. Heat treatment Heat treat the casting by normalizing, annealing, quench tempering, induction quenching, case hardening and nitriding per material spec. Machining Machine the castings by CNC according to drawing spec. Final inspection Test the parts’ mechanical properties by tension tester, impact tester, hardness tester, take NDT with X-ray, UT and M.P.T, final dimension inspection are down by CMM, Measures & Gauges, etc. Pack & Transport After rust prevention, pack the parts into plywood or iron case for transportation. This article was from Dandong Foundry. For the whole article, please check Dandong Foundry Blog. http://www.iron-foundry.com/lost-wax-investment-casting-process.html
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