Our Process

1.

Formation of Casting Die and Wax Pattern.

 

1. The Lost-Wax Casting starts by making a Aluminium Pattern considering Shrinkage Allowances for Wax pattern and Casting. In Addition, Machining Allowance are added to Required Features on the Casting Part.
2. It utilizes a pattern with the same details as the finished part, except that there is an allowance for thermal contraction (i.e. shrinking).
3. Patterns are typically made of wax using a metal injection die.

2.

Wax Pattern Quality Inspection

 

 

1. Patterns are checked for Wax Surface Finish Quality and Correct Dimensions to compensate casting shrinkage after pouring.

3.

Mounting The Wax Patterns And Creating The Tree

 

1. Once a wax pattern is produced, it is assembled with other wax components to form the gate and runner metal delivery system.
2. Depending on the size and configuration of the desired finish component, multiple wax patterns may be processed using a single tree.

4.

Creating The Mold Shell

 

1. The entire wax pattern assembly is dipped in a ceramic slurry, covered with sand stucco, and allowed to dry.
2. Cycles of wet dipping and subsequent stuccoing are repeated until a shell of the desired thickness is created. That thickness is partly dictated by product size and configuration.
3. Once the ceramic shell has dried, it becomes sufficiently strong to retain the molten metal during casting.
4. Constant monitoring of Shell Coating is carried out to fullfil requirements for Shell Strenght and Casting surface Quality.

5.

Wax Removal

 

1. The entire assembly is placed in a steam autoclave to melt away most of the wax.
2. Any remaining wax soaked into the ceramic shell is burned out in a furnace. At this point, the residual wax pattern and gating material have been completely removed and the ceramic mold remains with a cavity in the shape of the desired cast part.
3. This high-temperature operation also increases the strength and stability of the ceramic material. In addition, it helps to minimize the reaction of the shell and metal during pouring.
4. Inspection of Shell Mold is carried out for any cracks and Contaminants in the shell.

6.

Alloy Making and Melting

 

1. Pile of Scrap is filled in Framed Compartments with Designated Names on each Door.
2. The Scrap is cleaned for any Contaminants.
3. Proper Batch of Scrap, Ferro Alloys, De-Gasing Compounds and elements is weighted and prepared to achieve the Chemical Composition of Required Alloy.
4. The Batch is heated in a Induction Furnace upto a required temperature. After melting and achieving the required temperature, proper dirt, contaminants and macro-impurities removal is performed by using various slag removing compounds.
5. A Button sample is produce for each melt and checked for Required Chemical Composition.

7.

Shell Heating And Pouring

 

1. The mold is preheated to a specific temperature and filled with molten metal, creating the metal casting.

8.

Fetling and Heat Treatment

 

1. Once the casting has cooled sufficiently, the mold shell is broken away from the casting in a knockout operation.
2. The gates and runners are cut from the casting, and if necessary, final post-processing sandblasting, grinding, and machining is performed to finish the casting dimensionally.
3. The Casting is checked for any deviation in Form, Profile, Runout, Orientation and Location Control in geometry. Appropriate Post-Correction Actions are Performed and Checked to ensure All GD&T Requirements.
4. Final Heat Treatment Procedure on Casting is performed to achieve Uniform Properties in Part as per Respective Grade.

9.

Quality Assurance

1. A Final Inspection is performed on casting for Dimension requirement and Surface Defect.
2. Non-destructive testing can include Dye Penetrant, Magnetic Particle, radiographic, or other inspections. Final dimensional inspections, alloy test results, and NDT are verified prior to shipment.