Aluminum Investment Casting

Material Scope：
Aluminum:
ASTM-A319, A413, A355, A356, A357
JIS-AC2B, AC4D, AC4C, AC3A, AC4A
DIN-AlSi7cu4, AlSi5cu1Mg, AlSi7Mg, AlSi12, AlSi9Mg, AlSi12Cu2Mg1, AlSi6Cu4
ENAC-45000, 45300, 42100, 44100, 43300

In order to better provide one-stop service to our customers, Innovaw continues to maintain a high investment in research and development in the field of investment casting.

We will continue to introduce industry advanced investment casting equipment. We continue to improve the details of our investment casting process in practice, pursuing every ounce of progress.

We continue to study the material properties and the best application of different materials in the field of investment casting.

1. Overview of the process

- Pattern Creation: The process begins with the creation of a wax mold, which is an exact replica of the item to be cast. The pattern is usually made of wax because it is easily molded and then melted away. The wax mold is a replica of the final part geometry. A “master model” serves as a standard that can be reused in many casting cycles. Nowadays, engineers use advanced techniques such as 3D printing or die casting to manufacture patterns.

- Wax Mold Assembly and Formation: Multiple models are assembled into a single investment casting mold, and the combined pattern is called a “tree”. The operator then applies a layer of refractory material to the model to obtain the desired characteristics. The tree is repeatedly dipped into a bath of ceramic slurry and sand mortar in a gradual rotating manner. Through several such dipping cycles, the thickness of the ceramic shell around the wax model increases. Eventually a shell is formed around it, which hardens to form the mold.

- Wax removal: After the ceramic shell is formed, the wax inside the shell is removed by melting, leaving a cavity in the shape of the desired part.

- Casting: Molten metal is then poured into the ceramic mold. The metal fills the cavity left by the wax and takes the shape of the original pattern.

- Cooling and Finishing: Once the metal has cooled and solidified, the ceramic shell is broken to reveal the cast metal part. The part may then undergo additional finishing processes to achieve the desired specifications.

2. Advantages of Investment Casting

Investment casting is a highly versatile manufacturing process that offers several significant advantages:

- High Precision and Tolerances: Investment casting is renowned for its ability to produce parts with tight tolerances and intricate designs. This process can handle complex geometries that would be challenging to achieve with other casting methods, making it ideal for applications requiring high precision.

- Excellent Surface Finish: The process yields a smooth surface finish, which often reduces the need for extensive machining after casting. This characteristic not only enhances the aesthetic quality of the final product but also minimizes additional labor and costs associated with finishing operations.

- Reduced Machining Requirements: One of the key benefits of investment casting is its ability to significantly reduce machining time. Because the process produces parts that are closer to the final shape, less material needs to be removed, leading to quicker lead times and lower production costs.

- Design Freedom: The investment casting process provides greater design freedom, allowing for the creation of complex shapes and features that would be difficult or impossible to achieve with traditional methods. This flexibility enables engineers and designers to innovate without being constrained by manufacturing limitations.

- Consistency and Repeatability: Investment casting offers a high degree of repeatability, which is crucial for mass production. Once a mold is created, it can be used to produce numerous identical parts, ensuring consistent quality across large production runs.