The key benefits of manufacturing components using this versatile process
EDITOR ’ S CHOICE INVESTMENT CASTING
INVESTACAST
The key benefits of manufacturing components using this versatile process
Investment casting allows us to create highly intricate and complex components with virtually any alloy . It produces excellent dimensional accuracy , high integrity , and a fine surface finish , capable of meeting the demanding specifications of a wide range of industry sectors .
What is investment casting ? Investment casting derives its name from the process used to form the moulds . A series of wax patterns is assembled together and dipped (‘ invested ’) in tanks of liquid slurry alternated with ceramic stucco . This builds up layers that dry to form a ceramic mould .
The wax is melted away , then molten metal is carefully poured into the mould . After cooling under controlled conditions , the ceramic shell can be removed , and the cast metal parts finished to requirements .
The key benefits of investment casting
• Versatility of design Investment casting offers exceptional design flexibility . Complex components can be cast to near net shape , including internal shaping , undercuts and slots , and complex passageways . Thinner walls may be cast than is possible in other processes such as sand casting , leading to lower overall weight and improved efficiency .
• Versatility of materials Most alloy bases , such as ferrous , aluminium , nickel , copper and cobalt , are well-suited to investment casting . At Investacast , we are expert in air investment casting nickel-base superalloys . These alloys can be difficult to machine from solid , or to machine post-casting , and expensive to forge . Investment casting is the more economical manufacturing process of choice for components in these materials .
• Range of sizes and applications At Investacast we have cast components weighing from 10g to 30Kg , for applications from turbine blades to camera housings , for a wide range of industries . Tight tolerances Investment castings can be held to much tighter tolerances than sand castings or forgings : close dimensional tolerances down to +/ - 0.15mm / 25mm can be achieved .
• Exceptional surface finish Investment casting gives a very smooth finish thanks to the ceramic mould , typically offering 1.6 Ra to 3.2 Ra surface finish as cast . This can significantly reduce the amount of secondary machining , and therefore time , required compared to other manufacturing processes .
• Rapid prototyping Investacast ’ s rapid prototyping service allows companies to turn ideas
into products quickly and efficiently . We offer casting simulation and rapid production of prototypes to mitigate any risks when transitioning to production tooling .
• Low tooling costs
The investment casting process has much lower tooling set-up costs than gravity die or high pressure die casting , which require permanent casts to be manufactured . This makes it suitable for pre-production runs for high-volume pressure die cast products .
• Repeatability The quality of investment castings is maintained , providing a very reliable product and low-cost repeat runs .
• Sustainability
Investment castings are created to near net shape , and we recycle our wax , so production waste is minimal . Advice from the investment casting experts
Our expert team can advise on DfM and whether investment casting is the right manufacturing method for your components . Call + 44 ( 0 ) 1271 866200 or email info @ investacast . com
Find out more from the experts at www . investacast . com
36 PECM Issue 69