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Investment Casting

Investment casting, also know as lost wax casting is regarded as a precision casting process to fabricate near-net-shaped with components requiring complex shapes , often thin-wall , products which may not require future machining with accuracy, repeatability, versatility and integrity in a variety of metals and high-performance alloys.

Investment castings offer complex internal geometries, significant weight reduction opportunities, and unlimited alloy choices for the ultimate in design flexibility.

The reduction or elimination of secondary machining allows us to easily convert multi-part assemblies into single, as-cast parts with high rates of repeatability. Thin wall capabilities, smooth surface finishes, and consistent dimensional accuracies make investment casting the simple solution to complex engineering.

Wax is injected into an aluminum die to produce a pattern that is an exact replica of the part to be produced. For every casting, a wax pattern must be manufactured. The patterns are clustered around a coated sprue and repeatedly dipped into an agitated vat of ceramic and allowed to dry. After a shell thickness of approximately 3/16" has been built; the molds are dewaxed by either flash firing at high heat (1400 F.) or autoclaving (pressure and steam). The hollow shells are then preheated to 800-2000 F.depending on the alloy to be poured and the molten metal cast immediately into the hot shell. After cooling, the ceramic is vibrated and blasted off the metal parts and discarded. The balance of the cleaning operations (cut off, grind, heat treat, straightening, blast) are straight forward and quite similar to the other casting processes.

Why Investment Casting?

Advantages Limitations
Sand
Almost any metal cast, no limit to size,shape or weight and low tooling cost		 Sand
Some finishing required; somewhat coarse finish; wide tolerances
Shell Mould
Good dimensional accuracy and surface finish; high production rate		 Shell Mould
Part size limited; expensive patterns and equipment required
Expandable pattern
Most metal cast with no size limit, complex shapes cast easily		 Expandable pattern
Patterns have low strength and can be costly for low quantities.
Plaster Mould
Intricate shapes, good dimensional accuracy and finish, low porosity		 Plaster Mould
Limited to non-ferrous metals; limited size of volume and production; relatively long mould making time
Ceramic Mould
Intricate shapes, close tolerances part; good surface finish		 Ceramic Mould
Limited size
Investment
Intricate shapes; excellent surface finish and accuracy almost any metal cast		 Investment
Part size limited; expensive patterns, equipment and labour
Permanent Mould
Good dimensional accuracy and surface finish; high production rate; low porosity		 Permanent Mould
High mould cost; limited shape and intricact; not suitable for high melting point metals
Die
Excellent dimensional accuracy and surface finish; high production rates		 Die
High die cost; part size limited; usually limited to non-ferrous metals; long lead time
Centrifugal
Large cylindrical parts with good quality; high production rates		 Centrifugal
Equipment is expensive; part shape limited

Range and capacity

  • Weight from few gms. to 200 kgs. Single pcs.
  • Dimension up to 1000 mm length.
  • Material: Ferrous and Non-ferrous Alloys in all international standard.
  • Surface roughness will be 125 to 250 RMS.
  • Annual capacity of 250 M.T.

Features

  • Close dimension tolerances.
  • Excellent surface finish
  • Reduced machining.
  • Flexibility in ordering. Mahvir Technocast can offer of minimum quantities from 100 to maximum 20000 no of single item/ month.
  • Freedom of design, Mahavir Technocast can offer parts having a core, at very competitive price.
  • Eliminating general foundry defects.
  • Complexity of shape.

Value added services: Machining, Heat treatment, Plating (Zinc, Nickel, Chrome), Painting (powder and liquid paint), Phosphatising, and Blackening with ready to use assemblies and sub assemblies.

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