LATEST TRENDS IN INVESTMENT CASTING TECHNOLOGY

Dr.Ing.Milan Horek,PhD

Brno University of Technology, CZ

PAPER STRUCTURE
A/ Survey of foundry technologies available for casting manufacture B/ Basic principles of lost wax process investment casting C/ Brief history of the investment casting technology D/ Description of individual investment casting process phases
- wax pattern manufacture - ceramic shell manufacture - de-waxing - shell heat treatment - metal pouring - finishing operations

E/ Accuracy of investment casting technology F/ Capabilities of modern lost wax technology (examples of castings)

A/ SURVEY OF CASTING TECHNOLOGIES USING SAND MOULDING Ist . GENERATION - clay binders IInd. GENERATION chemical binding a/ Self-hardening processes (plaster,cement,sodium silicate,resin) b/ External hardening processes (sodium silicate, resin) c/ Ceramic moulds (mould firing before pouring) 1. Permanent pattern 2. Lost pattern

LOST FOAM

LOST WAX

IIIrd. GENERATION physical binding

B/ BASIC INVESTMENT CASTING PROCESS

Wax pattern making
Die

Wax pattern assembly

Wax pattern

Dipping into ceramic slurry

Wax pattern Gating system

Ceramic coating

Finished shell
Ceramic shell

De-waxing

Metal pouring

Removal of shell

Casting cut-off

C/ BRIEF HISTORY OF LOST-WAX PROCESS

p.n.l 0 n.l
Thajsko Mezopotmie Izrael Indie/S.V. Asie Anatlie na Egej / ecko Etrusko Keltsk S. Evropa man Jin/Stedn Amerika Zpadn Afrika Zpadn Evropa Renesann Itlie

5000

4000

3000

2000

1000

1000

2000

EXAMPLES OF HISTORICAL CASTINGS

gold comb casting (300g, Dniepr area, 4th cent.A.D.)

bronze head (Benin 12th.cent.A.D.) bronze statue of Perseus with Meduza head (Cellini, 1540)

D/ DESCRIPTION OF INDIVIDUAL PHASES OF INVESTMENT CASTING PROCESS

1. WAX PATTERN MANUFACTURE a/ Die manufacture b/ Wax pattern injection c/ Pattern assembly 2. CERAMIC SHELL MANUFACTURE a/ Step-by-step shell building and drying b/ Shell de-waxing c/ Ceramic shell firing 3. METAL POURING a/ On air b/ Under vacuum 4. FINISHING OPERATIONS a/ Gating system removal b/ Surface finish cleaning, blasting, etc.

1. WAX PATTERN MANUFACTURE a/ Master die making -Using master pattern

(using low-melt point alloys, by metal spraying, by galvanization)
Master pattern Sand mould Low melting point alloy Plaster METAL SPRAYING Master die

Low melting point alloy Sn,Bi,Pb,Cd Tmel=70C soft Tmel= 138C hard Master die

GALVANIZATION Low melting point alloy Metal master pattern

Ni,Cu,Fe by galvanization

-By machining from solid metal blocks

( the most often used method )

1. WAX PATTERN MANUFACTURE b/ Wax pattern making

WAXES USED Present waxes complex materials containing following components:
- natural waxes - syntetic waxes - natural resins - syntetic resins - organic fillers - water TYPES of WAXES - Straight (non-filled)

- Filled (30% of filler) - Emulsified

(by water, air)

Combination of different raw materials properties to achieve optimal wax characteristics:

-melting and congealing point -hardness -viscosity -expansion/contraction -solidification rate - ash content ( 0,05%) - flexibility - surface quality - stability to oxidation - possibility to recycle

BASIC PRINCIPLE OF INJECTION MACHINE FOR WAX PATTERN MAKING

Valve

Wax storage

Sp (piston surface) Transport wax hose

Piston pump

vc
Injection nozzle Piston Injection cylinder with wax Master die

EQUIPMENT FOR WAX PATTERN MAKING injection machine +wax melter + conditioner

INJECTION CYCLE
Speed controlled phase
1000

Pressure controlled phase

2
U (pre-set packing pressure)

E die cavity filling time K packing time N holding time Z cycle time (till the die opening)

Pressu re [bar]

NOTE: Points 1, 2, 3, 4 a 5 correspondent to the points in following picture

1a

Die opening

1
1

4 E K Z N

Time

INJECTION CYCLE

1 bar

Specif ic volum [cm3/ g]

1
200

1a
600 1000

4 3

2
1500

1 2 pressure increase in die cavity decrease of spec.volume 2 3 packing pressure slight decrease of spec.volume 3 4 pressure decrease during wax solidification constant spec. volume 4 5 wax cooling in die decrease of spec.volume (contraction)

5
NOTE:

vSP = 1/ specific volume [cm3/g] = 1/vSP density [g/cm3]

TE

(wax temperature during pattern stripping from die)

TM

(wax temperature during injection)

Temperature [C]

EXAMPLES OF INJECTION MACHINES

WAX PREPARATION FOR INJECTION

EXAMPLES OF WAX PATTERNS

1. MANUFACTURE OF WAX PATTERNS c/ Wax pattern assembly

Wax pattern assemblies
a) Horizontal placed patterns on a special gating rings

Assembly Design Influenced by:

-Technique of pattern assembly (glueing/welding) -Shelling technique -De-waxing technology
b) Patterns straight on gating sprue

-Pouring system -Casting cutting-off technique -Standartization of gating systems

2. MANUFACTURE OF CERAMIC SHELL a/ Shell building and drying

I/ DEGREASING OF WAX PATTERNS (removal of remaining separator from the wax pattern surface) II/ DIPPING INTO CERAMIC SLURRY (ceramic slurry consists of filler and binder) Filler heat resistant ceramic flour (fused silica,molochite,zircon,..) Binder colloidal silica sols based on alcohol (alcosols) or water (hydrosols) III/ SHELL DRAINING IV/ STUCCO APPLIED WITH CERAMIC GRIT ( fluid or rainfall systems) Stucco materials silica, molochite, alumina, zircon, atd. Grain size according to the coat number : - first 1-2 prime coats fine particles 0,175-0,25 mm (CASTING SURFACE FINISH) - next 3- x back-up coats coarser 0,25-0,5 mm (MOULD GAS PERMEABILITY) V/ SHELL DRYING (in aircondition room 2-4hours temp. 20 C 1 C , relative humidity 30-60% -according to the type of binder used, sufficient air flow) VI/ REPEATING ( II V) (till the needed number of coats 8-12)

SLURRY MIXING TANKS

SANDERS
Rainfall Fluidized bed

ROBOTIZIED SHELLING LINES

FULLY ROBOTIZED SHELLING LINE

2. MANUFACTURE OF CERAMIC SHELL b/ Shell de-waxing

KEY PROBLEM : different wax and shell expansion ! Wax expansion bigger,therefore danger of shell cracking during de-wax process. NECCESITY of dilatation gap building on wax pattern surface through THERMAL SHOCK see picture bellow.

TECHNIQUES USED FOR DE_WAXING I/ By overheated steam in boilerclaves II/ By firing flash fire system
CERAMIC SHELL Thermal expansion WAX PATTERN

III/ By microvave heating

2. MANUFACTURE OF CERAMIC SHELL b/ Shell de-waxing Majority foundries use boilerclave system
MAIN REASONS: -Ideal steam properties for heat transfer -Easy to collect de-waxed wax -High efficiency

Typical working parameters:

-Steam temperature 160-170C -Working pressure 6-8 atm -Reaching work.pressure in 4-5 s -Controlled speed of pressure drop

DE-WAXING IN BOILERCLAVE

WAX RECYCLING AFTER ITS DE-WAXING WAX RECYCLING

REMOVAL OF IMPURITIES + NEW WAX ADDITION

AUTOCLAVE

BOILER TANK 16 hours IMPURITIES

STORAGE TANK GEAR PUMP

MASTER DIE

2. MANUFACTURE OF CERAMIC SHELL c/ Shell firing

GOAL: transfer of amorphous type of SiO2 binder layer into a crystallic one + removal of volatiles matters (waxes remains)
1000
900 - 1080 C

900
60 80 min

800 700

5 C/min

Teplota [ C]

600 500 400

5 C/min

575 C

30 min

300 200 100 0 0 60 120 180 240 300 360

100 C 30 min

as [min]

DIFFERENT TYPES OF CERAMIC MOULDS MADE BY LOST WAX PROCESS

a) SOLID CERAMIC MOULD COMPACT METHOD

CERAMIC SLURRY a) SOLID CERAMIC MOULD COMBINED METHOD

SLURRY SAND (CEMENT)

2-3 SHELLS

c) BACKFILLED SHELL

d) SELF SUPPORTING SHELL

2-3 SHELLS

5-8 SHELLS

POSSIBILITIES OF USING CERAMIC CORES

Ceramic core manufacturing:

-Preparation of ceramic mass -Forming into a needed shape -Heat treatment

3. METAL POURING GRAVITY

a/ Classical pouring b/ Roll-overpouring
GRAVITY POURING

UNDER VACUUM
a/ Melting and gravity pouring under vacuum

b/ Counter-gravity pouring (CLA , CLV)

POURING UNDER VACUUM

VACUUM

VACUUM

VACUUM

POSSIBILITIES OF MOLTEN METAL FILTRATION

FILTRATION POSSIBILITIES 1.STRAINER CORES 3.EXTRUDED FILTERS

FILTER 2.FOAM FILTERS 4.GLASS FIBRES FILTERS

4. -

FINISHING OPERATIONS casting cut-off from gating system

(by vibration , cutting )

casting surface cleaning

(by blasting , grinding )

casting heat treatment

5. -

CASTING QUALITY INSPECTION chemical composition, structure

(spectrometr, metalography )

internal casting quality

(X-ray, ultrasonic )

casting surface finish

(capillar methods )

mechanical properties
(tensile strength, hardness, ductility, etc. )

dimensional accuracy

E/ DIMENSIONAL ACCURACY OF INVESTMENT CASTINGS

INVESTMENT CASTING PROCESS

(Lost wax process)

CASTING TECHNOLOGY A FINAL MACHINING SHOULD BE ELIMINATED NET SHAPE CASTING AS CAST CONDITIONS DIMENSIONAL AND TOLERANCE REQUIREMENTS

is

where

i.e. our goal is to achieve

to be ready for usage in

complying with all

The average tolerance exhibited by various casting processes (by J.Campbell)

THE FINAL CASTINGS DIMENSIONS

dependent on

Dimensional changes during individual stages of investment casting technology INVESTMENT CASTING PROCESS FINAL CASTING DIMENSIONS

PATTERN DIE DIMENSIONS

PATTERN DIE DIMENSION

must comply with

All subsequent dimensional changes during the process

i.e.

PATTERN MAKING SHELLING DE - WAXING SHELL DRYING and FIRING METAL POURING, SOLIDIFICATION and COOLING

DIMENSIONAL CHANGES DURING INVESTMENT CASTING PROCESS

tolerances dimension
c es toler an io n + Dimens

1 2 3 4

Tool cavity Wax pattern Dried shell Fired shell Final casting

S ta g p o e of ces t ss he

1 2 3

DIMENSIONAL ACCURACY OF INVESTMENT CASTINGS

F/ CAPABILITIES OF INVESTMENT CASTING TECHNOLOGY

EXAMPLES OF CASTINGS MADE BY LOST WAX TECHNOLOGY

Aircraft engine blade equiaxed structure, directional solidification, single crystal - superalloys Ni base, vacuum cast

Superalloys Ni base, vacuum cast -castings for power industry

Part of aircraft engine GE (Boeing 747,767) Ti alloy

EXAMPLES OF CASTINGS MADE BY LOST WAX TECHNOLOGY

Casing of tank control system Al alloy

Investment castings for shotgunCr hardenable stainless steel

Part of helicopter V-22 Ti alloy Boeing 777 APU duct- Ti alloy

EXAMPLES OF CASTINGS MADE BY LOST WAX TECHNOLOGY

Typical aluminium investment casting features

EXAMPLES OF CASTINGS MADE BY LOST WAX TECHNOLOGY

Investment vacuum castings for surgical implants ( knee and hip joints) - Ti6Al4V alloys , CoCrMo alloys

EXAMPLES OF ALUMINIUM INVESTMENT CASTINGS

SUBSTITUTION OF ORIGINAL TECHNOLOGY USED BY LOST WAX PROCESS

MACHINING+ WELDING +BENDING Weight 0,5 kg Material Fe alloy

INVESTMENT CASTING Weight 0,2 kg Material AlSi10 Mg

Dimensions 155x55x55 mm Benefit weight+ labour reduction, better part properties

1. part PLAST-2.part Al machined by milling+ screwed together Weight 0,11 kg Material: plast+ Al alloy

Investment casting
Weight 0,14 kg Material AlSi10 Mg

dimensions 100x40x30 mm Benefit labour less demanding, increased lifetime and component utility values

MACHINING -GLUEING Weight O,52 kg Material Al alloy

INVESTMENT CASTING Weight 0,32 kg Material: AlCu4 Ti

Dimensions 70x95x110 mm Benefits: labour less demanding, increased component utility values

MACHINING,WELDING Weight 0,15 kg Material Fe alloy

INVESTMENT CASTING Weight 0,03 kg Material AlSi10 Mg

Dimensions 40x40x40 mm Benefits: by 30% less labour demanding, increased part utility value

MACHINING,BENDING, WELDING Weight 0,05 kg Material Al alloy

INVESTMENT CASTING Weight 0,02 kg Material AlSi10 Mg

Dimensions: 55x40x40 mm Benefits: by 35% less labour , increased part utility value

PRESSURE DIE CASTING Weight 0,10 kg Material : Zn alloy

INVESTMENT CASTING Weight 0,04 kg Material: AlSi10 Mg

Dimensions:60x60x25 mm Savings: see next picture

SAND CASTING Weight 0,25 kg Material AlSi10 Mg

INVESTMENT CASTING Weight 0,20 kg Material AlSi10 Mg

Dimensions: 204x100x15 mm Savings: less labour cost and increase of component quality

SAND CASTING Weight - 4,8 kg Material - grey iron

INVESTMENT CASTING Weight 0,8 kg Material - AlSi7 Mg

Dimensions 240x130x40mm Benefit: Labour costs savings

MACHINING Weight of piece for mach. 3,36 kg Material Fe alloy

INVESTMENT CASTING Weight 0,12 kg Material - AlSi10 Mg

Dimensions 220x18 mm Benefit: labour costs savings

SAND CASTING Weight 2,4 kg Material RR 350 ( AlCu5Ni)

INVESTMENT CASTING Weight 1,8 kg Material RR 350 (AlCu5Ni)

Dimensions: 150x150x110 mm Benefits: weight reduction, increase of engine power by app. 15 %

INVESTMENT CASTING AGAINST PRESSURE DIE CASTING

ECONOMICAL COMPARISON OF CORNER CASTING

Inv.Cast. (CzCrowns) Die price 1.000 pcs 10.000 pcs 15.000 pcs 30.000 45.000 450.000 675.000

Press.Die (CzCrowns) 460.000 16.000 160.000 240.000

IC(total)

PD(total)

75.000 480.000 705.000

476.000 620.000 700.000

BREAK-EVEN POINT IS app. 15.000 pcs In other words only over this amount of castings is PD technology more economical

AIRCRAFTS WITH MIKRON ENGINES (www.parmatechnik.cz)

SAND CASTING Weight 8,7 kg (45 kg) Material. Fe alloy

INVESTMENT CASTING Weight 2,7 kg Material:AlSi7 Mg T6

Dimensions: 260x260x100 mm Savings: on material and labour

SAND CASTING Weight 0,9 kg Material Fe alloy

INVESTMENT CASTING Weight 0,4 kg Material AlSi7 Mg T6

Dimensions 150x80x60 mm Benefit: weight reduction and less labour during machining

Customer: Tadiran Communications Title: Body 9004 Dimensions: 234 x 318 x 201 mm Material: A 356 Weight: 3,5 Kg

Customer: BMT Title: Support Dimensions: 190 x 301 x 240 mm Material: A 356 Weight: 1,33 Kg

Customer: Borcad Title: Rack Dimensions: 304 x 337 x 57 mm Material: A356 Weight: 0,82 Kg

Customer: Uniplet Title: Cover Dimensions: 209 x 360 x 118 mm Material: A356 Weight: 1,25 Kg

Customer: Wyman-Gordon Dimensions: 518 x 147 x 32 mm

Title: Ramback side Material: A 357

Weight: 1,38 Kg

THANK YOU FOR YOUR ATTENTION HAVE A NICE DAY !