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Process

Wax Preparation

  • Wax patterns are made with the use of different types of industrial wax.
  • Wax will have some set quality parameters like melting point, Congealing point, and Ash Content.
  • Once the wax is ready for use, transferred to the tank of the injection machine.
  • Wax tanks with a capacity of 200 Ltrs. to 600 Ltrs.

Wax Pattern Injection

  • Liquid wax injection into a molding tool having the desired shape of the final product for making wax pattern.
  • One wax pattern represents one casting part.
  • The wax pattern has to comply with esthetically and dimensionally requirements for qualifying for the next process.
  • Manual and semi-automatic wax injection presses with a capacity of 3 Ton to 20 tons.

Wax Pattern Assembly

  • The Wax patterns are allied with gate, runner, cup and struts according to the size and shape of the pattern.
  • Each part of the entire assembly having its specific role and the correctness must be verified before use.
  • Assembly unit with capacity of 50 MT per month.

Ceramic Coating

  • Ceramic coatings applied on the assembly, the first coat will apply with ceramic slurry and very fine sand.
  • Balance coats applied with different refractory at regular intervals.
  • Temperature and humidity control must required at entire coating zone.
  • Slurry tank and fluidized sand bed having size as Ø600mm to Ø900mm with dust collector.

De-waxing

  • Wax pattern assembly with no. of coatings converted into shell after de-waxing.
  • Wax inside the solid ceramic coatings being removed in liquid form with applying pressurized steam.
  • Steam pressure and cycle time are very critical parameters to be controlled during the de-waxing.
  • Autoclave with IBR approved steam boiler.

Melting/Pouring

  • Shells are preheated and filled by pouching the liquid metal.
  • Induction melting furnace used for preparing the molten metal and poured with use of ladles.
  • Chemical composition, shell temperature, pouring temperature, pouring speed, purity of metal, etc. are very critical parameters to be controlled.
  • Induction furnace of 175 kw with 150 kg. & 250 kg. crucible and immersion pyrometer.

Finishing

  • Ceramic structure being removed with pneumatic vibrator casted parts separated from gate and runners.
  • Burs, fins and other surface dis continuities removed during fettling.
  • Aesthetic look and proper dimensions of the casting are the output of this process.
  • Pneumatic vibrator, Abrasive cut off machine and more.

Heat Treatment

  • Mechanical properties as per standard can be achieved by heat treatment process.
  • Material should get prior heat treatment according to standard requirement.
  • Process cycle time, soaking time, cooling method and media are very critical process parameters to be controlled.
  • Gas fired heat treatment furnace with capacity of 500 kg and data logger.