What Is an Investment Casting Foundry?

Posted on Dec 4, 2020

investment casting foundry

Investment casting is a casting method based on lost-wax casting. It one of the oldest metal-forming techniques that has been around for centuries. In this article, we'll specifically look at the place in which the process takes place – investment casting foundry.

What is an investment casting foundry?

It is a place where the investment casting process takes place. The process works by applying materials such as ceramic and wax to shape a molded shell to apply to the metal component, which is why it’s also called lost wax casting.

By applying investment casting to the materials, we are capable of producing highly intensified castings like stainless steel. These products are guaranteed to acquire delicate details and impressive durability. The investment casting process will be cutting down the time and cost for another machinery or secondary processing.

If you’re looking for an investment opportunity, implementing investment casting can be quite a good choice. The investment casting process features cutting down the waste of material and can finish the casting within less time. It wouldn’t be a bad idea to find out how your factory would be reshaped and reborn with providing a better quality of intensified and precise merchandise for your customers. This ultimate goal would be based on this spectacular one-way manufacturing and production strategy of the investment casting process.

:: Read more : A Brief Introduction to Casting Foundry

How does the foundry operate?

The investment casting process generally starts with the design applied with a wax pattern. The technicians tend to initially provide the leading programs and their profession to shape the model within a very small tolerance of length. There would be expecting a surface finish standard, which would be situated at the range of 130-165 rms. In the final stage, the completion of lost wax casting would be in the tolerance of shrinkage, which means the final product might not meet the expectation of presuming dimensions.

In the following stage, the ceramic shell would be built and surround the completed pattern. It would be very close and suitable to address the description of the related technology of shell molding as the state of art. The present process of lost wax casting is set to meet the exact specifications of sizes and other abiding requirements from the clients. This would be managed with the process of dipping the mold in a ceramic slurry, which would be stucco and sand.

Next, a ceramic shell is assembled around the pattern. Our state-of-the-art robotic technology creates a shell mold to the exact specifications needed for the material and size requirements of your piece. This is achieved by alternately dipping the mold in a ceramic slurry.

The process of dewaxing would start as long as the shell completes its process of fulfilling the ideal thickness and is fully dried. The intensive heat would be applied to the various ovens for melting the wax mold. It could also collaterally clean the interior of your ceramic shell.

The final shape of the shell is at the moment completely prepared for filling the molten metal. Straightly pour the molten metal into its interior. The temperature is crucial to the final completion of metal because of the alloy characteristics. The final stage is to remove the ceramic shell to unveil the metal product. The entire foundry would save you 45-55% of the cost than simply welding the component you need.

Pros and cons of investment casting

See the advantages and disadvantages of investment casting below: 

● The investment casting process is able to create an excellent surface finish. By observing the completion of metal, there would be usually a performance with extraordinary dimensional precision. 
● The most extremely intricate parts of the casting target are castable. 
● The exclusive method of investment casting process can be applied to a wide range of metal casting.  
● There would be no flash or parting lines during the process.

● The cost of the foundry, especially for short-running manufacture, is the major disadvantage of the method. High costs basically result from refractories, binders, and even specialized equipment. However, the total cost would still be lower than bar stock production. For example, gun manufacturers choose this type of foundry to lower the cost of the pistol production line.  
● The process has its difficulty casting objects that require cores. 
● The holes within the workpieces shall be smaller than 1.6 mm and can’t be deeper than 1.5 times the diameter. 
● It requires a lengthy production cycle compared to other processes. 

Other types of casting processes

Counter-gravity casting
The process of counter-gravity casting would be provided with a downward fill pipe to the mold. The pipe itself is lower into the molten metal. There would be a vacuum drawing the melt into a cavity, waiting for the base to solidify. After witnessing the solidification, the operator would release the vacuum, putting the unused materials away.

The one main idea of counter-gravity casting would be to take the assistance of pressure differential so that the metal could flow into every intricacy from the mold. In the end, the lower temperature would be applied to the metal in order to improve the grain structure within the body. Some of the processes require fewer materials than gravity pouring. 

Vacuum pressure casting
The VPC, which stands for vacuum pressure casting, is a technique that applies the gas pressure and the vacuum to enhance the quality and strength that the casting can achieve. It is sometimes referred to as vacuum assist direct pour. Normally, the vacuum pressure casting contains the upper and lower chamber in the machines. the upper chamber is in charge of melting and the crucible. The lower chamber, however, houses the investment mold. Some common materials like superalloys or the high nickel-based alloy would be perfect for vacuum pressure casting.

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