Investigating the Effect of Shape Factor, Slurry Layers and Pouring Temperature in Precision Investment Casting

2013 ◽  
Vol 751 ◽  
pp. 35-44 ◽  
Author(s):  
Rupinder Singh ◽  
Jagdeep Singh
Keyword(s):  
Surface Roughness ◽  
Investment Casting ◽  
Shape Factor ◽  
Surface Hardness ◽  
Dimensional Accuracy ◽  
Casting Process ◽  
Pouring Temperature ◽  
Controllable Factors ◽  
Investment Casting Process ◽  
Single Response

This paper aimed to investigate the effect of shape factor, slurry layers and pouring temperature in precision investment casting. Three controllable factors of the precision investment casting process (namely: shape factor, slurry layers (mold thickness) and pouring temperature) were studied at three levels each by Taguchis parametric approach and single-response optimization was conducted to identify the main factors controlling surface hardness, dimensional accuracy (Δd) and surface roughness (Ra). Castings were produced using aluminum (Al), mild steel (M.S.) and stainless steel (S.S) at recommended parameters through ceramic shell precision investment casting process. The micro structure analysis has been used to study the surface morphology. Analysis shows that for surface hardness, contribution of shape factor, slurry layers and pouring temperature is 0.07%, 0.70% and 99% respectively. As regards to surface roughness, contribution of shape factor, slurry layers and pouring temperature is 1.14%, 16.80% and 81.90% respectively. Further for Δd contribution of shape factor, slurry layers and pouring temperature is 1.53%, 22.47% and 72.88% respectively. Confirmation experiments were conducted at an optimal condition showed that the surface hardness, Δd and Ra of the precision investment casting were improved significantly.

Investigations for Mechanical Properties of Hybrid Investment Casting: A Case Study

2014 ◽  
Vol 808 ◽  
pp. 89-95 ◽  
Author(s):  
Parlad Kumar ◽  
Rupinder Singh ◽  
I.P.S. Ahuja
Keyword(s):  
Investment Casting ◽  
Fused Deposition Modeling ◽  
Dimensional Accuracy ◽  
Casting Process ◽  
Manufacturing Processes ◽  
Biomedical Implant ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
Investment Casting Process

Conventional investment casting is one of the old manufacturing processes. It involves expensive tooling for making sacrificial wax patterns to make ceramic moulds. However, with the emergence of rapid prototyping technologies, now it is possible to make and use plastic patterns instead of wax patterns along with some advantages. In this paper, plastic patterns have been prepared by using fused deposition modeling and used for investment casting process. A case study has been discussed to make a biomedical implant by the hybridization of fused deposition modeling with investment casting. Dimensional accuracy, surface finish and hardness of the casted biomedical implants have been tested and reported.

Enhancement of Porosity of the Ceramic Shell in Investment Casting Process Using Needle Coke and Camphor

2014 ◽  
Vol 592-594 ◽  
pp. 269-275 ◽  
Author(s):  
Khyati Tamta ◽  
D. Benny Karunakar
Keyword(s):  
Investment Casting ◽  
Complex Geometry ◽  
Gas Permeability ◽  
Ferrous Metal ◽  
Dimensional Accuracy ◽  
Casting Process ◽  
Ceramic Shell ◽  
Needle Coke ◽  
Thin Sections ◽  
Investment Casting Process

Investment casting process has been a widely used process for centuries. It is known for its ability to produce components of complex shapes with dimensional accuracy and excellent surface finish. Investment casting has been used to make manufacture weapons, jewellery and art castings during the ancient civilization and today it is used to manufacture engineering components. In Investment casting wax patterns are made by wax injection and then coating of the wax patterns are done by ceramic slurry, made with silica flour and binder. After dewaxing and firing molten metal is poured in the shell and solidified casting can be achieved. Investment casting can be cast any ferrous and non ferrous metal which is difficult in die casting. Finishing operations are negligible and very thin sections as.75mm can also be cast which is not possible in sand casting but there are many challenges in Investment casting. It is relatively slow process because preparation of ceramic shell consumes a lot of time, permeability of shell is very low which causes gas permeability. Incorporation of chills is very difficult. Among all these challenges gas porosity is main problem because of poor permeability, entrapment of gases due to complex geometry of the shell, reuse of scrap metal. In the present work porosity of the shell can be increase by addition of mixture of Camphor and needle coke. After firing of the shell camphor and needle coke will be burnt leaving pores for the escape of entrapped gases. Mechanical properties of the both shell will be compared with each other.

Study of Shell Cracking Behavior and its Remedies in Investment Casting Process Using Quick Cast Rapid Prototype Polymer Patterns

2012 ◽  
Vol 710 ◽  
pp. 214-219
Author(s):  
Ankit Sharma ◽  
Mayukh Acharya ◽  
Alok Agarwal ◽  
Govind ◽  
S.C. Sharma ◽  
...  
Keyword(s):  
Rapid Prototyping ◽  
Investment Casting ◽  
Rapid Prototype ◽  
Dimensional Accuracy ◽  
Casting Process ◽  
Cost Effective ◽  
Direct Conversion ◽  
Cracking Behavior ◽  
Engineering Changes ◽  
Investment Casting Process

Investment casting has emerged as the foremost casting process for manufacturing of intricate parts where better dimensional accuracy is required. Use of rapid prototyping polymer patterns is one of the major advancements in investment casting process. Elimination of die making step as required in the traditional wax process makes it quicker and a cost effective process. The direct conversion of 3D CAD data into rapid prototyping pattern decreases development time, chances of costly mistakes, minimizes sustaining engineering changes and extend product lifetime by adding necessary features and eliminating redundant features early in the design.

Formulations, development and characterization techniques of investment casting patterns

2019 ◽  
Vol 35 (3) ◽  
pp. 335-349 ◽  
Author(s):  
Robert K. Tewo ◽  
Hilary L. Rutto ◽  
Walter Focke ◽  
Tumisang Seodigeng ◽  
Lawrence K. Koech
Keyword(s):  
Investment Casting ◽  
Manufacturing Sector ◽  
Dimensional Accuracy ◽  
Casting Process ◽  
Thermomechanical Analysis ◽  
Mechanical Analysis ◽  
Filler Materials ◽  
Scanning Calorimetry ◽  
Investment Casting Process ◽  
Printed Patterns

Abstract Conventionally, unfilled wax has been used as a universal pattern material for the investment casting process. With increase in demand for accurate dimensions and complex shapes, various materials have been blended with wax to develop more suitable patterns for investment casting in order to overcome performance limitations exhibited by unfilled wax. The present article initially reviews various investigations on the development of investment casting patterns by exploring pattern materials, type of waxes and their limitations, the effect of filler materials and various additives on unfilled wax, wax blends for pattern materials, plastics and polymers for pattern materials and 3D-printed patterns. The superiority of filled and polymer patterns in terms of dimensional accuracy, pattern strength, surface and flow properties over unfilled wax is also discussed. The present use of 3D patterns following their versatility in the manufacturing sector to revolutionize the investment casting process is also emphasized. Various studies on wax characterization such as physical (surface and dimensions), thermal (thermogravimetric analysis and differential scanning calorimetry), mechanical (thermomechanical analysis, tensile stress testing, dynamic mechanical analysis) and rheological (viscosity and shearing properties) are also discussed.

scholarly journals Investment Casting vs Replicast CS Considered in Terms of the Ceramic Mould Making and Dimensional Accuracy of Castings

2014 ◽  
Vol 14 (1) ◽  
pp. 45-48 ◽  
Author(s):  
A. Karwiński ◽  
R. Haratym ◽  
R. Biernacki ◽  
A. Soroczyński
Keyword(s):  
Investment Casting ◽  
Dimensional Accuracy ◽  
Casting Process ◽  
Ceramic Materials ◽  
Fused Silica ◽  
Crystalline Quartz ◽  
Linear Dimensions ◽  
Zirconium Silicate ◽  
Wide Range ◽  
Investment Casting Process

Abstract The article presents an analysis of the applicability of the Replicast CS process as an alternative to the investment casting process, considered in terms of the dimensional accuracy of castings. Ceramic shell moulds were based on the Ekosil binder and a wide range of ceramic materials, such as crystalline quartz, fused silica, aluminosilicates and zirconium silicate. The linear dimensions were measured with a Zeiss UMC 550 machine that allowed reducing to minimum the measurement uncertainty

Electropolishing of Orthodontic Bracket Produced by Investment Casting Process

2016 ◽  
Vol 842 ◽  
pp. 397-401 ◽  
Author(s):  
Sugeng Supriadi ◽  
Tito W. Sitanggang ◽  
Bambang Irawan ◽  
Bambang Suharno ◽  
Tjokro Prasetyadi ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Investment Casting ◽  
Casting Process ◽  
Orthodontic Brackets ◽  
Metal Injection Molding ◽  
Tooth Decay ◽  
Orthodontic Bracket ◽  
Difficulty Breathing ◽  
Common Technique ◽  
Investment Casting Process

Malocclusion or improper teeth arrangement is the most common problem in the field of orthodontics. If the malocclusion is not corrected, it will promote more serious problems, such as bleeding gums, tooth decay, cavities, difficulty breathing and other problems. Currently, the most common technique used to cure the malocclusion is using treatment of orthodontic brackets. Normally, orthodontic brackets can be produced by machining, metal injection molding and investment casting processes. In the previous research, orthodontic brackets have been successfully produced using investment casting process. The investment casting is selected, since the technology was developed well in Indonesia which is shown by existing number of investment casting industries. However, surface roughness of the bracket produced by investment casting is still high, valued at 0.91 μm. On the other hand, surface roughness of the commercial orthodontic bracket is 0.53 μm. In this current work is focused on surface modification of investment casting brackets by using electropolishing. The best result shows that the surface roughness of cast brackets achieve up to 0.44 μm. It shows that opportunity to fabricate orthodontic brackets domestically is applicable.

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