Microfusion Investment Casting
Microfusion Investment Casting in India
Microfusion in India is done at Sumangal Casting Pvt. Ltd. which is located at Rajkot – the biggest hub of investment casting in India. It’s nearest to the international air and seaports.
The investment casting processes and system is approved by the world’s leading and notifying agencies and this puts us far ahead in the local competitive market. The products manufactured in our manufacturing plant follow the international standards and are made as per the requirements of the domestic and international OEMs and all the products are treated with the same expertise and experience.
You can rest assured that you are buying high-quality approved products that can be safely used as parts of any machinery.
Microfusion investment casting process
Microfusion investment casting is useful when you want to achieve even the minutest details in the products. The products obtained by using this casting process carry the detailing of complex undercuts and dimensional accuracy with complete precision.
Here’s a brief outlook of the process of microfusion investment casting and how it’s done at our company.
Tool preparation - First a tool or die is made with the help of machines. The cavity in the tool is in the same pattern as the original cast and then the pressurized wax is filled in the cavity to obtain the wax pattern. For this process, aluminium alloys are most commonly used as they can are easy in handling, cool easily, high strength, and easy machining.
Wax pattern creation- Mostly petroleum wax is used for pattern creation. It’s melted and prepared following the QCP requirement of the wax pattern and is in semi-liquid form. After melting the wax is injected in the hollow tool. This is done by first feeding the pattern wax into the hydraulic injection press followed by injecting it into the hollow tool. Then the wax is allowed to get cooled and solidified.
Shell or cluster making and ceramic coating -After completion of the pattern, assembly is made by the process of making runner, riser, and spur. These are made by wax to wax extrusion press. The model is then coated with ceramic slurry by dipping it into the slurry. The process is repeated many times to attain the desired thickness. This repetitive process is known as the secondary process and it provides strength to the model.
Dewaxing, melting and pouring - The shell is placed in a pressured chamber called a dewaxing autoclave. Then in the chamber, steam is injected at high pressure which melts the wax, and then the melted wax is removed from the shell.The shell is then baked in a furnace and made compatible to withstand the high temperature of liquid metal that will be poured into it. When the shell has gained the strength to sustain the melted metal then the melted metal is poured into it.
Shell removal- After the poured metal gets cooled down and solidified the outer ceramic shell is removes by breaking it into the pieces. Hammer machine is used for the removal of the shell in the process of the knockout. The metal cast is then removed and goes for the heat treatment process to achieve the mechanical properties of the casting.
Fettling, machining and assembly- Grit blasting and pneumatic grinding are used to give final finishing to the metal cast. IN CNC and VMC the finished casting is duly machined. Semi assembly and machined casting are done.
Final inspection, packaging and dispatch of the product-We conduct visual tests for 100% finished products to check them on all the parameters to assure the quality and standard of the final finished product. After inspection, the metal product is now ready for packaging, and dispatch.