In this process, all metal alloys are available, we can customize investment castings according to customer’s material specifications, and even material compositions is feasible for production. To ensure the best quality, each investment casting process are inspected and have quality control in . General steps of the whole investment casting process in our foundry as below,
1.Casting Solidification Simulation
Casting solidification simulation is the simulation analysis of mold filling, heat conduction and solidification process before actual casting. Based on the solidification simulation , it can greatly reduce waste in casting.
The simulation of multiphase flow is the basis of simulating the mold filling process of casting. It includes the calculation and analysis of entrapment gas, oxidation inclusion, sand erosion and exhaust gas in the die casting process.
It also takes into account the complicated flow of turbulent flow , surface tension, free surface, phase transition, heat exchange and many other factors, and the simulation results are closer to the real casting process.TCC proceed this process before production .
2.Wax Injection and Pattern Assembly
The qualified wax mold (after the quality inspection process) is assembled to the die head to make a complete gating system — commonly known as the tree string. Tools are generally made of thin copper plate about 1-2 mm thick iron. There are many control points that need to be paid attention to when forming trees, such as the spacing of the workpiece, the inclination of the workpiece, the technique and strength of forming trees, etc., because the process of forming trees may affect the post-stage processes such as soaking, dewaxing, replenishing and cutting. So the group tree process requires a certain amount of experience.
3.Shell Building
In this step, the pattern assembly will be dipped into a ceramic slurry and coated with a refractory material. It has to be repeated several times until reaching the required certain thickness and strength, then ,these pattern assemblies will be hold in the cooling room with controlled temperature until drying.
4.Melting and Pouring
Casting is the key step in the whole investment casting process. The steel ingots is melt with liquid status and poured into the the sprue, then solidified in the air and the products similar to the mold cavity are obtained.
5.Cleaning
Break the ceramic shell, and cut the individual investment castings from the sprue. Finally remove the excess metal from casting body by grinding.
Heat treatment is one of the most important process to guarantee the mechanical properties of casting blanks . It usually proceed after the castings is finished. The popular heat treatment processes eg, Normalizing, tempering, annealing, hardening and tempering, carburizing etc. The heat treatment is not necessary until the customer has such requirements.
With the strong mechanical capacity in TCC, all the casting blanks are machined in our factory. It is our strength compare to other casting foundry.
Inspection is mandatory process in TCC to secure the quality. Our engineer will do dimensional inspection, 100% surface inspection, inner defects inspection and other inspection jobs according to requirements of products. With certificated inspector and equipments , RT, MT and PT can be inspected in our factory.
9.Packaging
All the products are well packed, normally , the key parts will be protected particularly , then each products will be packed with ploybags , bubble bags or foams, each layer will be separated with paper board , then be put in the standard plywood cases. All the packing must be carried out on the basis of free from damage. the weight and the dimension of each case will follow the packaging requirement of customers.