LATEST TRENDS IN INVESTMENT CASTING TECHNOLOGY. Dr.Ing.Milan Horáček,PhD Brno University of Technology, CZ
|
|
|
- Rose Curtis
- 5 years ago
- Views:
Transcription
1 LATEST TRENDS IN INVESTMENT CASTING TECHNOLOGY Dr.Ing.Milan Horáček,PhD Brno University of Technology, CZ
2 PAPER STRUCTURE A/ Survey of foundry technologies available for casting manufacture B/ Basic principles of lost wax process investment casting C/ Brief history of the investment casting technology D/ Description of individual investment casting process phases - wax pattern manufacture - ceramic shell manufacture - de-waxing - shell heat treatment - metal pouring - finishing operations E/ Accuracy of investment casting technology F/ Capabilities of modern lost wax technology (examples of castings)
3 A/ SURVEY OF CASTING TECHNOLOGIES USING SAND MOULDING Ist. GENERATION - clay binders IInd. GENERATION chemical binding a/ Self-hardening processes (plaster,cement,sodium silicate,resin) b/ External hardening processes (sodium silicate, resin) c/ Ceramic moulds (mould firing before pouring) 1. Permanent pattern 2. Lost pattern LOST FOAM LOST WAX IIIrd. GENERATION physical binding
4 B/ BASIC INVESTMENT CASTING PROCESS Wax pattern making Wax pattern assembly Dipping into ceramic slurry Die Wax pattern Wax pattern Gating system Ceramic coating Finished shell De-waxing Ceramic shell Metal pouring Removal of shell Casting cut-off
5 C/ BRIEF HISTORY OF LOST-WAX PROCESS p.n.l 0 n.l Thajsko Mezopotámie Izrael Indie/S.V. Asie Anatólie Čína Egej / Řecko Etrusko Keltská S. Evropa Římané Jižní/Střední Amerika Západní Afrika Západní Evropa Renesanční Itálie
6 EXAMPLES OF HISTORICAL CASTINGS gold comb casting (300g, Dniepr area, 4th cent.a.d.) bronze head (Benin 12th.cent.A.D.) bronze statue of Perseus with Meduza head (Cellini, 1540)
7 D/ DESCRIPTION OF INDIVIDUAL PHASES OF INVESTMENT CASTING PROCESS 1. WAX PATTERN MANUFACTURE a/ Die manufacture b/ Wax pattern injection c/ Pattern assembly 2. CERAMIC SHELL MANUFACTURE a/ Step-by-step shell building and drying b/ Shell de-waxing c/ Ceramic shell firing 3. METAL POURING a/ On air b/ Under vacuum 4. FINISHING OPERATIONS a/ Gating system removal b/ Surface finish cleaning, blasting, etc.
8 1. WAX PATTERN MANUFACTURE a/ Master die making -Using master pattern (using low-melt point alloys, by metal spraying, by galvanization) Master pattern METAL SPRAYING Master die Sand mould Plaster Low melting point alloy Low melting point alloy Sn,Bi,Pb,Cd T mel =70 C soft T mel = 138 C hard Master die GALVANIZATION Low melting point alloy Metal master pattern Ni,Cu,Fe by galvanization -By machining from solid metal blocks ( the most often used method )
9 1. WAX PATTERN MANUFACTURE b/ Wax pattern making WAXES USED Present waxes complex materials containing following components: - natural waxes TYPES of WAXES - syntetic waxes - natural resins - Straight (non-filled) - syntetic resins - Filled (30% of filler) - organic fillers - Emulsified -water (by water, air) Combination of different raw materials properties to achieve optimal wax characteristics: -melting and congealing point - ash content ( 0,05%) -hardness - flexibility -viscosity - surface quality -expansion/contraction - stability to oxidation -solidification rate - possibility to recycle
10 BASIC PRINCIPLE OF INJECTION MACHINE FOR WAX PATTERN MAKING Valve Wax storage S p (piston surface) Piston pump Transport wax hose v c Injection nozzle Piston Injection cylinder with wax Master die
11 EQUIPMENT FOR WAX PATTERN MAKING injection machine +wax melter + conditioner
12 INJECTION CYCLE 1000 Speed controlled phase Pressure controlled phase 2 U (pre-set packing pressure) 3 τ E die cavity filling time τ K packing time τ N holding time τ Z cycle time (till the die opening) Pressu re [bar] NOTE: Points 1, 2, 3, 4 a 5 correspondent to the points in following picture 1a Die opening τ E τ K τ N Time τ Z
13 INJECTION CYCLE Specif ic volum [cm 3 / g] a 2 1 bar pressure increase in die cavity decrease of spec.volume 2 3 packing pressure slight decrease of spec.volume 3 4 pressure decrease during wax solidification constant spec. volume 4 5 wax cooling in die decrease of spec.volume (contraction) 5 NOTE: v SP = 1/ρ specific volume [cm 3 /g] ρ = 1/v SP density [g/cm 3 ] T E (wax temperature during pattern stripping from die) T M (wax temperature during injection) Temperature [ºC]
14 EXAMPLES OF INJECTION MACHINES
15 WAX PREPARATION FOR INJECTION
16 EXAMPLES OF WAX PATTERNS
17 1. MANUFACTURE OF WAX PATTERNS c/ Wax pattern assembly Wax pattern assemblies a) Horizontal placed patterns on a special gating rings Assembly Design Influenced by: -Technique of pattern assembly (glueing/welding) -Shelling technique -De-waxing technology b) Patterns straight on gating sprue -Pouring system -Casting cutting-off technique -Standartization of gating systems
18 2. MANUFACTURE OF CERAMIC SHELL a/ Shell building and drying I/ DEGREASING OF WAX PATTERNS (removal of remaining separator from the wax pattern surface) II/ DIPPING INTO CERAMIC SLURRY (ceramic slurry consists of filler and binder) Filler heat resistant ceramic flour (fused silica,molochite,zircon,..) Binder colloidal silica sols based on alcohol (alcosols) or water (hydrosols) III/ SHELL DRAINING IV/ STUCCO APPLIED WITH CERAMIC GRIT ( fluid or rainfall systems) Stucco materials silica, molochite, alumina, zircon, atd. Grain size according to the coat number : - first 1-2 prime coats fine particles 0,175-0,25 mm (CASTING SURFACE FINISH) - next 3- x back-up coats coarser 0,25-0,5 mm (MOULD GAS PERMEABILITY) V/ SHELL DRYING (in aircondition room 2-4hours temp. 20 C ±1 C, relative humidity 30-60% -according to the type of binder used, sufficient air flow) VI/ REPEATING ( II V) (till the needed number of coats 8-12)
19
20 SLURRY MIXING TANKS
21 SANDERS Rainfall Fluidized bed
22 ROBOTIZIED SHELLING LINES
23 FULLY ROBOTIZED SHELLING LINE
24 2. MANUFACTURE OF CERAMIC SHELL b/ Shell de-waxing KEY PROBLEM : different wax and shell expansion! Wax expansion bigger,therefore danger of shell cracking during de-wax process. NECCESITY of dilatation gap building on wax pattern surface through THERMAL SHOCK see picture bellow. TECHNIQUES USED FOR DE_WAXING I/ By overheated steam in boilerclaves II/ By firing flash fire system CERAMIC SHELL WAX PATTERN Thermal expansion III/ By microvave heating
25 2. MANUFACTURE OF CERAMIC SHELL b/ Shell de-waxing Majority foundries use boilerclave system MAIN REASONS: -Ideal steam properties for heat transfer -Easy to collect de-waxed wax -High efficiency Typical working parameters: -Steam temperature C -Working pressure 6-8 atm -Reaching work.pressure in 4-5 s -Controlled speed of pressure drop
26 DE-WAXING IN BOILERCLAVE
27 WAX RECYCLING AFTER ITS DE-WAXING WAX RECYCLING REMOVAL OF IMPURITIES + NEW WAX ADDITION AUTOCLAVE BOILER TANK 16 hours IMPURITIES STORAGE TANK MASTER DIE GEAR PUMP
28 2. MANUFACTURE OF CERAMIC SHELL c/ Shell firing GOAL: transfer of amorphous type of SiO2 binder layer into a crystallic one + removal of volatiles matters (waxes remains) ºC/min ºC min 700 Teplota [ ºC] ºC/min 575 ºC 30 min ºC 30 min Čas [min]
29 DIFFERENT TYPES OF CERAMIC MOULDS MADE BY LOST WAX PROCESS a) SOLID CERAMIC MOULD COMPACT METHOD CERAMIC SLURRY a) SOLID CERAMIC MOULD COMBINED METHOD SLURRY SAND (CEMENT) 2-3 SHELLS c) BACKFILLED SHELL d) SELF SUPPORTING SHELL 2-3 SHELLS 5-8 SHELLS
30 POSSIBILITIES OF USING CERAMIC CORES Ceramic core manufacturing: -Preparation of ceramic mass -Forming into a needed shape -Heat treatment
31 GRAVITY 3. METAL POURING UNDER VACUUM a/ Classical pouring b/ Roll-over pouring a/ Melting and gravity pouring under vacuum b/ Counter-gravity pouring (CLA, CLV) GRAVITY POURING POURING UNDER VACUUM VACUUM VACUUM VACUUM
32 POSSIBILITIES OF MOLTEN METAL FILTRATION FILTRATION POSSIBILITIES 1.STRAINER CORES 3.EXTRUDED FILTERS FILTER 2.FOAM FILTERS 4.GLASS FIBRES FILTERS
33 4. FINISHING OPERATIONS - casting cut-off from gating system (by vibration, cutting ) - casting surface cleaning (by blasting, grinding ) - casting heat treatment 5. CASTING QUALITY INSPECTION - chemical composition, structure (spectrometr, metalography ) - internal casting quality (X-ray, ultrasonic ) - casting surface finish (capillar methods ) - mechanical properties (tensile strength, hardness, ductility, etc. ) - dimensional accuracy
34 E/ DIMENSIONAL ACCURACY OF INVESTMENT CASTINGS INVESTMENT CASTING PROCESS (Lost wax process) is CASTING TECHNOLOGY where A FINAL MACHINING SHOULD BE ELIMINATED i.e. our goal is to achieve NET SHAPE CASTING to be ready for usage in AS CAST CONDITIONS complying with all DIMENSIONAL AND TOLERANCE REQUIREMENTS
35 The average tolerance exhibited by various casting processes (by J.Campbell)
36 THE FINAL CASTING S DIMENSIONS dependent on Dimensional changes during individual stages of investment casting technology INVESTMENT CASTING PROCESS PATTERN DIE DIMENSIONS FINAL CASTING DIMENSIONS
37 PATTERN DIE DIMENSION must comply with All subsequent dimensional changes during the process PATTERN MAKING i.e. SHELLING DE - WAXING SHELL DRYING and FIRING METAL POURING, SOLIDIFICATION and COOLING
38 DIMENSIONAL CHANGES DURING INVESTMENT CASTING PROCESS tolerances dimension 1 Tool cavity Dimension Dimension + tolerances tolerances Wax pattern 3 Dried shell 4 Fired shell 5 Final casting Stage Stage of the pocesss pocesss
39 DIMENSIONAL ACCURACY OF INVESTMENT CASTINGS
40 F/ CAPABILITIES OF INVESTMENT CASTING TECHNOLOGY
41 EXAMPLES OF CASTINGS MADE BY LOST WAX TECHNOLOGY Aircraft engine blade equiaxed structure, directional solidification, single crystal - superalloys Ni base, vacuum cast Superalloys Ni base, vacuum cast -castings for power industry Part of aircraft engine GE (Boeing 747,767) Ti alloy
42 EXAMPLES OF CASTINGS MADE BY LOST WAX TECHNOLOGY Casing of tank control system Al alloy Investment castings for shotgun- Cr hardenable stainless steel Boeing 777 APU duct- Ti alloy Part of helicopter V-22 Ti alloy
43 EXAMPLES OF CASTINGS MADE BY LOST WAX TECHNOLOGY Typical aluminium investment casting features
44 EXAMPLES OF CASTINGS MADE BY LOST WAX TECHNOLOGY Investment vacuum castings for surgical implants ( knee and hip joints) - Ti6Al4V alloys, CoCrMo alloys
45 EXAMPLES OF ALUMINIUM INVESTMENT CASTINGS SUBSTITUTION OF ORIGINAL TECHNOLOGY USED BY LOST WAX PROCESS
46 MACHINING+ WELDING +BENDING Weight 0,5 kg Material Fe alloy INVESTMENT CASTING Weight 0,2 kg Material AlSi10 Mg Dimensions 155x55x55 mm Benefit weight+ labour reduction, better part properties
47 1. part PLAST-2.part Al machined by milling+ screwed together Weight 0,11 kg Material: plast+ Al alloy dimensions 100x40x30 mm Investment casting Weight 0,14 kg Material AlSi10 Mg Benefit labour less demanding, increased lifetime and component utility values
48 MACHINING -GLUEING INVESTMENT CASTING Weight O,52 kg Weight 0,32 kg Material Al alloy Material: AlCu4 Ti Dimensions 70x95x110 mm Benefits: labour less demanding, increased component utility values
49 MACHINING,WELDING INVESTMENT CASTING Weight 0,15 kg Weight 0,03 kg Material Fe alloy Material AlSi10 Mg Dimensions 40x40x40 mm Benefits: by 30% less labour demanding, increased part utility value
50 MACHINING,BENDING, WELDING Weight 0,05 kg Material Al alloy Dimensions: 55x40x40 mm INVESTMENT CASTING Weight 0,02 kg Material AlSi10 Mg Benefits: by 35% less labour, increased part utility value
51 PRESSURE DIE CASTING INVESTMENT CASTING Weight 0,10 kg Weight 0,04 kg Material : Zn alloy Material: AlSi10 Mg Dimensions:60x60x25 mm Savings: see next picture
52 SAND CASTING INVESTMENT CASTING Weight 0,25 kg Weight 0,20 kg Material AlSi10 Mg Material AlSi10 Mg Dimensions: 204x100x15 mm Savings: less labour cost and increase of component quality
53 SAND CASTING INVESTMENT CASTING Weight - 4,8 kg Weight 0,8 kg Material - grey iron Material - AlSi7 Mg Dimensions 240x130x40mm Benefit: Labour costs savings
54 MACHINING INVESTMENT CASTING Weight of piece for mach. 3,36 kg Weight 0,12 kg Material Fe alloy Material - AlSi10 Mg Dimensions Ø 220x18 mm Benefit: labour costs savings
55 SAND CASTING INVESTMENT CASTING Weight 2,4 kg Weight 1,8 kg Material RR 350 ( AlCu5Ni) Material RR 350 (AlCu5Ni) Dimensions: 150x150x110 mm Benefits: weight reduction, increase of engine power by app. 15 %
56 INVESTMENT CASTING AGAINST PRESSURE DIE CASTING ECONOMICAL COMPARISON OF CORNER CASTING Inv.Cast. (CzCrowns) Press.Die (CzCrowns) Die price IC(total) PD(total) pcs pcs pcs BREAK-EVEN POINT IS app pcs In other words only over this amount of castings is PD technology more economical
57 AIRCRAFTS WITH MIKRON ENGINES (
58 SAND CASTING INVESTMENT CASTING Weight 8,7 kg (45 kg) Weight 2,7 kg Material. Fe alloy Material:AlSi7 Mg T6 Dimensions: 260x260x100 mm Savings: on material and labour
59 SAND CASTING Weight 0,9 kg Material Fe alloy INVESTMENT CASTING Weight 0,4 kg Material AlSi7 Mg T6 Dimensions 150x80x60 mm Benefit: weight reduction and less labour during machining
60 Customer: Tadiran Communications Title: Body 9004 Dimensions: 234 x 318 x 201 mm Material: A 356 Weight: 3,5 Kg
61 Customer: BMT Title: Support Dimensions: 190 x 301 x 240 mm Material: A 356 Weight: 1,33 Kg
62 Customer: Borcad Title: Rack Dimensions: 304 x 337 x 57 mm Material: A356 Weight: 0,82 Kg
63 Customer: Uniplet Title: Cover Dimensions: 209 x 360 x 118 mm Material: A356 Weight: 1,25 Kg
64 Customer: Wyman-Gordon Dimensions: 518 x 147 x 32 mm Title: Ramback side Material: A 357 Weight: 1,38 Kg
65 THANK YOU FOR YOUR ATTENTION HAVE A NICE DAY!
Types of moulding sand
casting Types of moulding sand 1. Green sand: Green sand which is also known as natural sand is the mostly used sand in moulding. It is basically the mixture of sand, clay and water. The clay contain
Metal Casting Processes CHAPTER 11 PART I
Metal Casting Processes CHAPTER 11 PART I Topics Introduction Sand casting Shell-Mold Casting Expendable Pattern Casting Plaster-Mold Casting Introduction Metal-Casting Processes First casting were made
Understanding Investment Casting Wax. Richard Hirst Sales & Marketing Manager Blayson Olefines Ltd
Understanding Investment Casting Wax Richard Hirst Sales & Marketing Manager Blayson Olefines Ltd Agenda The Blayson Group Ltd What is Investment Casting Wax? Structure of Investment Casting Wax Categories
Special Casting. By S K Mondal
Special Casting By S K Mondal Shell Moulding The sand is mixed with a thermosetting resin is allowed to come in contact with a heated metal pattern (200 0 C). A skin (shell) of about 3.5 mm of sand and
(( Manufacturing )) Fig. (1): Some casting with large or complicated shape manufactured by sand casting.
(( Manufacturing )) Expendable Mold Casting Processes: Types of expendable mold casting are: 1 ) Sand casting. 2 ) Shell molding. 3 ) Vacuum molding. 4 ) Investment casting. 5 ) Expanded polystyrene process.
Solidification Processes
CASTING PROCESSES I Lecture Notes by Zulkepli Muhamad Solidification Processes Starting work material is either a liquid or is in a highly plastic condition, and a part is created through solidification
1.0 PRECISION CASTING PROCESSES
1.0 PRECISION CASTING PROCESSES An Introduction to precision casting processes The casting process is without equal as the manufacturing cable of producing fully shaped components of any size in any
Intensification of Mechanical Properties of the Investment Shell Using Camphor
Intensification of Mechanical Properties of the Investment Shell Using Camphor 1 Khyati Tamta, 2 D. Benny Karunakar 1 Student, 2 Assistant Professor 1 Mechanical and Industrial Engineering Department,
CHAPTER 4: METAL CASTING PROCESS
CHAPTER 4: METAL CASTING PROCESS CHAPTER OUTLINE 4.1 INTRODUCTION 4.2 EXPANDABLE MOLD CASTING PROCESSES 4.2.1 Sand Casting 4.2.2 Shell Molding 4.2.3 Plaster Mold Casting 4.2.4 Ceramic Mold Casting 4.2.5
Manufacturing Processes - I Dr. D. B. Karunakar Department of Mechanical and Industrial Engineering Indian Institute of Technology, Roorkee
Manufacturing Processes - I Dr. D. B. Karunakar Department of Mechanical and Industrial Engineering Indian Institute of Technology, Roorkee Lecture - 5 Metal Casting Good morning. In the earlier episodes,
BMM3643 Manufacturing Processes Metal Casting Processes (Expendable Mold & Permanent Mold)
BMM3643 Manufacturing Processes Metal Casting Processes (Expendable Mold & Permanent Mold) by Dr Mas Ayu Bt Hassan Faculty of Mechanical Engineering masszee@ump.edu.my Chapter Information Lesson Objectives:
SHELL MOULDING & INVESTMENT CASTING
SHELL MOULDING & INVESTMENT CASTING SHELL MOULDING Thisistheprocessinwhichthesandmixedwiththermosettingresinisallowedtocomein contact with the heated metallic pattern plate. This is done so that a thin
Two Categories of Metal Casting Processes
Two Categories of Metal Casting Processes 1. Expendable mold processes - mold is sacrificed to remove part Advantage: more complex shapes possible Disadvantage: production rates often limited by time to
AATC PRESENTATION INVESTMENT CASTING PROCESS (2 OF 3 PRESENTATIONS REVISION 2014_0429) AATC, Inc W. Catalina Dr. Phoenix, AZ USA
AATC PRESENTATION INVESTMENT CASTING PROCESS (2 OF 3 PRESENTATIONS REVISION 2014_0429) 1 Wax Injection & Pattern Assembly Wax Injection: A wax pattern is made by injecting liquid wax into an aluminum mold.
Casting Process Part 1
Mech Zone Casting Process Part 1 (SSC JE Mechanical/ GATE/ONGC/SAIL BHEL/HPCL/IOCL) Refractory mold pour liquid metal solidify, remove finish Casting - Process of Producing Metallic Parts by Pouring Molten
Interfacial Reaction between Magnesium Alloy and magnesia Ceramic Shell Mold
Interfacial Reaction between Magnesium Alloy and magnesia Ceramic Shell Mold S. Madhav Reddy* and A. Chennakesava Reddy** *Assistant Professor, Department of Mechanical Engineering MGIT, Hyderabad, India
Manufacturing Processes - I Dr. D. B. Karunakar Department of Mechanical and Industrial Engineering Indian Institute of Technology, Roorkee
Manufacturing Processes - I Dr. D. B. Karunakar Department of Mechanical and Industrial Engineering Indian Institute of Technology, Roorkee Lecture - 4 Module 2 Metal Casting Good morning, Metal casting,
Company Profile. Company Profile PRECISION INVESTMENT CASTING MANUFACTURER
INTRODUCTION Adroit Techno cast Pvt. Ltd. (ATCPL) is a versatile manufacturer, capable of producing highly customized products in the field of Investment Casting. Catering to quality-conscious niches,
(Refer Slide Time: 00:35)
Fundamentals of Materials Processing (Part 1) Professor Shashank Shekhar Department of Materials Science and Engineering Indian Institute of Technology, Kanpur Lecture Number 02 Solidification (Casting)
Test Bench for Analyzing the Lost Foam Process
A R C H I V E S of F O U N D R Y E N G I N E E R I N G Published quarterly as the organ of the Foundry Commission of the Polish Academy of Sciences ISSN (1897-3310) Volume 13 Issue 1/2013 57 62 11/1 Test
600 Cannonball Lane O Fallon, MO Bruce Willson.
600 Cannonball Lane O Fallon, MO 63366 Bruce Willson http://www.ofalloncasting.com/ Definition of an Engineer o Someone who knows almost everything o About almost nothing 70 95% of total Product Cost is
4.1.3: Shell Casting.
4.1.3: Shell Casting. It is another expandable mold casting type; Shell molding is a casting process in which the mold is a thin shell (typically 9mm) made of sand held together by a thermosetting resin
Manufacturing Processes - I Dr. D. B. Karunakar Mechanical and Industrial Engineering Department Indian Institute of Technology, Roorkee
Manufacturing Processes - I Dr. D. B. Karunakar Mechanical and Industrial Engineering Department Indian Institute of Technology, Roorkee Module - 2 Lecture - 7 Metal Casting Good morning. We have been
Casting Processes. ver. 2
Casting Processes ver. 2 1 Types of Parts Made Engine blocks Pipes Jewelry Fire hydrants 2 Complex, 3-D shapes Near net shape Low scrap Relatively quick process Intricate shapes Large hollow shapes No
Special Casting Process. 1. Permanent mould casting
Special Casting Process 1. Permanent mould casting A permanent mold casting makes use of a mold or metallic die which is permanent.molten metal is poured into the mold under gravity only and no external
Investment Casting with PolyCast
Application Note Investment Casting with PolyCast 1. Overview PolyCast is an entirely new 3D printing filament designed specifically for investment casting applications. This document provides the basic
Guideline. Casting Selection Process. Table of Contents. Delivery Engineered Solutions
Casting Selection Process Guideline Table of Contents Introduction... 2 Factors In Choosing A Process... 2 Category Details & Requirements... 4 Sand casting... 4 Gravity die casting (also known as permanent
Manufacturing: Chapter 3 Casting
CHAPTER THREE Metal Casting Casting, shown in Fig. 3.1, is the process of pouring molten metal into a mould containing a cavity, which represents the required product shape. It is one of the most commonly
BMM3643 Manufacturing Processes Metal Casting Processes (Sand Casting)
BMM3643 Manufacturing Processes Metal Casting Processes (Sand Casting) by Dr Mas Ayu Bt Hassan Faculty of Mechanical Engineering masszee@ump.edu.my Chapter Synopsis This chapter will expose students to
Solidification Process(1) - Metal Casting Chapter 9,10
Solidification Process(1) - Metal Casting Chapter 9,10 Seok-min Kim smkim@cau.ac.kr -1- Classification of solidification processes -2- Casting Process in which molten metal flows by gravity or other force
CASTING Fundamentals. Prepared by Associate Prof. Mohamed Ahmed Awad Cairo, 2014
CASTING Fundamentals Prepared by Associate Prof. Mohamed Ahmed Awad Cairo, 2014 Casting Definition Casting is the process of pouring molten metal into a mould containing a cavity, which represents the
A CONCEPTUAL DESIGN OF PATTERN TO REPLACE INVESTMENT CASTING
A CONCEPTUAL DESIGN OF PATTERN TO REPLACE INVESTMENT CASTING THESIS SUBMITTED IN THE FULFILLMENT FOR THE DEGREE OF Bachelor of Technolgy In Mechanical Engineering By LOKANATH BEHERA 109ME0360 Department
Module-2: ADVANCED METAL CASTING PROCESSES:
Module-2: ADVANCED METAL CASTING PROCESSES: Lecture No-3 Hybrid Evaporative Pattern Casting Process One of the limitations of EPC process is that the sand, which is free flowing, falls on the unfilled
Chapter 1 Sand Casting Processes
Chapter 1 Sand Casting Processes Sand casting is a mold based net shape manufacturing process in which metal parts are molded by pouring molten metal into a cavity. The mold cavity is created by withdrawing
Manufacturing Process II. Casting-3
Manufacturing Process II Casting-3 Casting Processes Metal casting processes divide into two categories, based on mold type: (1) expendable mold and (2) permanent mold. In expendable mold casting operations,
Metal Mould System 1. Introduction
Metal Mould System 1. Introduction Moulds for these purposes can be used many times and are usually made of metal, although semi-permanent moulds of graphite have been successful in some instances. The
Influence of Wax Pattern Surface Quality on Prime Coat of Ceramic Mold
A R C H I V E S of F O U N D R Y E N G I N E E R I N G Published quarterly as the organ of the Foundry Commission of the Polish Academy of Sciences ISSN (1897-3310) Volume 14 Special Issue 1/2014 67-72
AATC PRESENTATION - COMPANY (1 OF 3 PRESENTATIONS REVISION 2014_0429) AATC, Inc W. Catalina Dr. Phoenix, AZ USA
AATC PRESENTATION - COMPANY (1 OF 3 PRESENTATIONS REVISION 2014_0429) 1 Investment Casting s About AATC Quality Commitment Management We want your business Investment castings reduce or eliminate alternate
MANUFACTURING PROCESSES
1 MANUFACTURING PROCESSES - AMEM 201 Lecture 10: Casting Technology DR. SOTIRIS L. OMIROU CASTING - Basics - A material in a liquid or semisolid form is poured or forced to flow into a die cavity and allowed
The dimensional and shape accuracy of vacuum castings prepared in plaster moulds
A R C H I V E S of F O U N D R Y E N G I N E E R I N G Published quarterly as the organ of the Foundry Commission of the Polish Academy of Sciences ISSN (1897-3310) Volume 11 Issue 3/2011 143 148 24/3
Castings. 65tons, 7m high, 43cm dia, 1600years old
Castings 65tons, 7m high, 43cm dia, 1600years old At 500/550 pound in weight. The biggest Gravity Die Casting in The World at the Time http://www.rainwater.demon.co.uk/bertha.htm CASTING AND RELATED PROCESSES
Creating Quality Casting
MME 6203 Lecture 01 Creating Quality Casting AKMB Rashid Professor, Department of MME BUET, Dhaka Topics to discuss today. 1. Defects in casting 2. How to create quality casting 3. Introducing MME 6203
1 ZSI Product Experience Examples
www.zsind.com 1 ZSI Product Experience Examples www.zsind.com 2 Casting and machining (1) 1 Material: Grey Iron GG25 Process: Sand Casting Vacuum Pump 2 Material: Cast Iron GG25, GGG40 Process: Sand Casting
Applying RP-FDM Technology to Produce Prototype Castings Using the Investment Casting Method
A R C H I V E S of F O U N D R Y E N G I N E E R I N G Published quarterly as the organ of the Foundry Commission of the Polish Academy of Sciences ISSN (1897-3310) Volume 12 Issue 3/2012 75 82 14/3 Applying
In this study, it hopes to use recycled ceramic shell mould as refectory coating materials and geopolymer technology to shorten the process of coating
A Study on Recycling and Application Waste Ceramic Shell Mould by Using Geopolymer Technology Yi-Fong Wu a, Ta-Wui Cheng a, Steve Hsu b, Gary Hsu b a: National Taipei University of Technology b: Chips
SAND CASTING LMU., MEC 329,MECH., DEPT. ADEDIRAN A.A
SAND CASTING Sand Casting is simply melting the metal and pouring it into a preformed cavity, called mold, allowing (the metal to solidify and then breaking up the mold to remove casting. In sand casting
The properties that are generally required in molding materials are:
Molding Sand Molding sands may be of two types namely natural or synthetic. Natural molding sands contain sufficient binder. Whereas synthetic molding sands are prepared artificially using basic sand molding
FRANKLIN BRONZE PRECISION COMPONENTS
FRANKLIN BRONZE PRECISION COMPONENTS FRANKLIN BRONZE PRECISION COMPONENTS AN AUTOMATED INVESTMENT CASTING FOUNDRY OFFERING TOOLING, MACHINING AND TECHNICAL EXPERTISE. DELIVERING HIGH-QUALITY, CONSISTENT
Drivetrain for Vehicles 2018
Drivetrain for Vehicles 2018 presentation of an innovation RoBoC = Roll Bond Core ADVANTAGES OFFER RoBoC - Keep the stator housing battery housing power unit housing junction box and other similar applications
Japan Foundry Society, Inc. Research and Application of EPS Investment Casting Technique. Lu Dingquan Donfeng Investment Casting Co., Ltd.
Japan Foundry Society, Inc. Research and Application of EPS Investment Casting Technique Lu Dingquan Donfeng Investment Casting Co., Ltd. 13 th WORLD CONFERENCE ON INVESTMENT CASTING Paper: T11 Copyright
Attention is drawn to the following places, which may be of interest for search:
CPC - B22D - 2017.08 B22D CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection
Metal Casting Dr. D. B. Karunakar Department of Mechanical and Industrial Engineering Indian Institute of Technology, Roorkee
Metal Casting Dr. D. B. Karunakar Department of Mechanical and Industrial Engineering Indian Institute of Technology, Roorkee Module - 02 Sand Casting Process Lecture - 02 Moulding Sands And Design-I Good
METAL CASTING PROCESSES
METAL CASTING PROCESSES Sand Casting Other Expendable Mold Casting Processes Permanent Mold Casting Processes Foundry Practice Casting Quality Metals for Casting Product Design Considerations Two Categories
EFFECT OF PROCESS VARIABLES ON THE QUALITY OF INVESTMENT CASTINGS PRODUCED BY USING EXPANDABLE POLYSTYRENE PATTERN
EFFECT OF PROCESS VARIABLES ON THE QUALITY OF INVESTMENT CASTINGS PRODUCED BY USING EXPANDABLE POLYSTYRENE PATTERN A DISSERTATION Submitted in partial fulfillment of the requirements for the award of the
Introduction to Manufacturing Processes
Introduction to Manufacturing Processes Products and Manufacturing Product Creation Cycle Design Material Selection Process Selection Manufacture Inspection Feedback Typical product cost breakdown Manufacturing
CBN abrasives for demanding grinding applications in automotive, aerospace and oil & gas. TOOLMAKER SOLUTIONS Borazon CBN
CBN abrasives for demanding grinding applications in automotive, aerospace and oil & gas TOOLMAKE SOLUTIONS Borazon CBN BOAZON CBN Hyperion s family of Borazon cubic boron nitride (CBN) products achieves
Advantages of the Casting Process
Advantages of the Casting Process The casting process has nearly unlimited flexibility compared to other manufacturing processes and is excellent for optimizing designs based on performance and weight
Casting. Pattern Making and Molding
Casting Pattern Making and Molding Introduction Virtually nothing moves, turns, rolls, or flies without the benefit of cast metal products. The metal casting industry plays a key role in all the major
Additive Manufacturing. amc.ati.org
Additive Manufacturing amc.ati.org Traditional Tooling 356-T6 lever casting for DSCR Wood pattern on matchboard Additive Manufacturing (AM) A new term but the technology is almost three decades old Formerly
Steel Plate in Oil Rig Blowout Preventer Valves
Design Problem Steel Plate in Oil Rig Blowout Preventer Valves Introduction Design for Performance Alloy selection Radii and stress reduction Design for Production Mould method Orientation and cores Controlling
Multiple-Use-Mold Casting Processes
Multiple-Use-Mold Casting Processes Chapter 13 13.1 Introduction In expendable mold casting, a separate mold is produced for each casting Low production rate for expendable mold casting If multiple-use
Materials & Processes in Manufacturing
Materials & Processes in Manufacturing ME 151 Chapter 15 Multiple Use Mold Casting Processes 1 Introduction Expendable Molds - melting point materials and castings General shortcomings of the expendable-mold
rapid casting development with simulation and QMC
1 Rapid casting development by means of Qualified Master Casting (QMC) and numerical simulation modeling Dr. Joachim Gundlach Grunewald 2008 2 1. Grunewald 2. Rapid Prototyping techniques 3. casting development
CASTING. Dept. of Mech & Mfg. Engg. 1
CASTING 1 CASTING It is the process of producing metallic parts by pouring a molten metal in to the mould cavity and allowing the metal to solidify. 2 Casting Process Pattern making Mould making Metal
Principles of Major Manufacturing Processes. Prepared by: Behzad Heidarshenas Ph.D in Manufacturing Processes
Principles of Major Manufacturing Processes Prepared by: Behzad Heidarshenas Ph.D in Manufacturing Processes 1 Overview of Casting Technology Casting is usually performed in a foundry Foundry = factory
Innovative Dewax Method Unlocks Potential for Investment Casters
Innovative Dewax Method Unlocks Potential for Investment Casters Abstract Tom Branscomb Buntrock Industries, Inc. Totally new methods are infrequent in a mature industry like investment casting. However,
Permanent Mold Casting Processes. Assoc Prof Zainal Abidin Ahmad Department of Manufacturing & Ind. Eng.
Assoc Prof Zainal Abidin Ahmad Department of Manufacturing & Ind. Eng. Universiti Teknologi Malaysia Permanent Mold Casting Processes Gravity die casting Pressure die casting Low pressure High pressure
ME 4563 ME 4563 ME 4563
Introduction to Manufacturing Processes College of Engineering Arkansas State University 1 Casting Processes for Liquid Metals There are two classes of casting processes: Ingot casting - simple shapes
What makes Investment Casting one of the BEST way to cast metal?
What makes Investment Casting one of the BEST way to cast metal? In it s simplest form, investment casting can be thought of as the melting and flowing of any of todays common engineering metals and alloys
Expendable-Mold Casting Process
Expendable-Mold Casting Process Chapter 12 12.1 Introduction Factors to consider for castings Desired dimensional accuracy Surface quality Number of castings Type of pattern and core box needed Cost of
INTRODUCTION. HareeshaN G Lecturer Department of aeronautical engg. Classification of manufacturing process
INTRODUCTION HareeshaN G Lecturer Department of aeronautical engg Classification of manufacturing process 2 Blore 1 Classification of manufacturing process 3 Types of production systems Mass production
AMTECH INVESTMENT CASTING
A REPORT OF INDUSTRIAL VISIT AT AMTECH INVESTMENT CASTING Organized By Mechanical Engineering Department Om Institute Of Engineering & Technology, Junagadh (5 th Sem Diploma Students,Date on 16 th SEPTEMBER,
Think quality. Think global
Think quality. Think global B.B. Investment Casting Manufactures : Precision Lost Wax Investment Castings (Feinguss - Micro Fusione) VISION THE COMPANY, AT A GLANCE At B.B. Investment Casting, we commit
Copyright 1999 Society of Manufacturing Engineers FUNDAMENTAL MANUFACTURING PROCESSES Casting
Copyright 1999 Society of Manufacturing Engineers --- 1 --- FUNDAMENTAL MANUFACTURING PROCESSES Casting SCENE 1. CG: FBI warning white text centered on black to blue gradient SCENE 2. CG: disclaimer white
The Design of Gating System 2. Introduction to the gating system
MME 345 Lecture 14 The Design of Gating System 2. Introduction to the gating system Ref: [1] P. Beeley, Foundry Technology, Butterworth-Heinemann, 2001 [2] J. Campbell, Castings, Butterworth-Heinemann,
ABSTRACT I. INTRODUCTION II. METHODS AND MATERIAL
2017 IJSRSET Volume 3 Issue 2 Print ISSN: 2395-1990 Online ISSN : 2394-4099 Themed Section: Engineering and Technology A Critical Review on Casting Types and Defects T. Venkat Sai 1, T. Vinod 2, Gunda
DULUX UNIVERSAL UNDERCOAT
TECHNICAL DATA SHEET Version 1 2015 JUNE THIS ISSUE SUPERSEDES ALL PREVIOUS PUBLICATIONS PRODUCT DESCRIPTION Intermediate coating for use under decorative topcoats, for interior and exterior use PRODUCT
Schematic set-up of sand molding / casting process
UNIT I Casting Processes The casting process involves pouring of liquid metal in to a mold cavity and allowing it to solidify to obtain the final casting. The flow of molten metal into the mold cavity
ABOUT ALLIED. Global Refractory Solutions. About. Research & Technology. MINRO Investment Powders
ABOUT ALLIED About Allied Mineral Products is a world leader in the design and manufacture of monolithic refractories and precast shapes. With strong sales and service teams in the foundry, aluminum, steel,
Technical Data Sheet ACRYLIC FILLER 4:1 Acrylic filler with anti-corrosion additives RELATED PRODUCTS. Acrylic and polyurethane thinner
Acrylic filler with anti-corrosion additives RELATED PRODUCTS Acrylic filler hardener Acrylic and polyurethane thinner PROPERTIES A product designed and dedicated for renovation of classic cars Universal
1 Component Casting 1.1 INTRODUCTION
1 Component Casting 1.1 Introduction 1 1.1.1 History of Casting 1 1.1.2 Industrial Component Casting Processes 1 1.2 Casting of Components 1 1.2.1 Production of Moulds 1 1.2.2 Metal Melt Pressure on Moulds
foamcast CASTING PROCESS jayshree machines & tools
foamcast CASTING PROCESS foamcast Process Steps 1. Mold foam pattern sections. 2. Age pattern to allow dimensional shrinkage. 3. Assemble pattern if it is a multiple piece pattern. 4. Build cluster (multiple
Design and Technology Resistant materials Key words and definitions
Design and Technology Resistant materials Key words and definitions Word Acrylic Definition a type of thermoplastic, which is hard and can be transparent. Used to make shop signs. Perspex is a trade/brand
6043 DESIGN AND TECHNOLOGY
www.onlineexamhelp.com www.onlineexamhelp.com CAMBRIDGE INTERNATIONAL EXAMINATIONS GCE Ordinary Level MARK SCHEME for the October/November 2013 series 6043 DESIGN AND TECHNOLOGY 6043/01 Paper 1, maximum
FLAP DISCS FLAP DISCS
FLAP DISCS FLAP DISCS 63 Flap discs normal corundum G-A perfect Normal corundum Reasonably priced product suitable for grinding steel and wood. Tough, hard abrasive grain permits good removal capacity,
Extrusion. Process. The photo below shows a typical thermoplastic extruder.
Extrusion This process can be compared to squeezing toothpaste from a tube. It is a continuous process used to produce both solid and hollow products that have a constant cross-section. E.g. window frames,
Guide for Casting Titanium with SuperCast Contents
Contents Contents... 1 Introduction:... 2 Flask Preparation Process... 2 Prepare the wax-up model... 2 Preparing the metal flask... 2 Mixing the investment... 3 Vacuuming the mixture... 4 Solidifying the
ME0203- Manufacturing Technology
ME0203- Manufacturing Technology Casting and Welding Metal Casting A large sand casting weighing 680 kg for an air compressor frame Basic Features n Pattern and Mould A pattern is made of wood or metal,
INDUTHERM Mini Vacuum Pressure Casting Machine MC 20V
INDUTHERM Mini Vacuum Pressure Casting Machine MC 20V Advanced induction heated casting machine for all standard alloys like gold, silver steel, palladium and platinum alloys are possible to cast. MC 20
Centrifugal Casting Machine Company, Inc.
Centrifugal Casting Machine Company, Inc. The world leader in centrifugal casting and permanent mold technology Est. 1940 Art the The Centrifugal Casting Machine Company, Inc. (CCMCO) is the established
Capability directory. At the forefront of castings technology. castingstechnology.com
Capability directory At the forefront of castings technology castingstechnology.com Contents Overview 3 esign for casting 4 Titanium castings Vacuum induction melting castings 6 Replicast and precision
Casting Process Lec byprof. A.Chandrashekhar
Casting Process Lec 18-20 byprof. A.Chandrashekhar Introduction casting may be defined as a metal object obtained by pouring molten metal in to a mould and allowing it to solidify. Casting process is
special line perfect line evolution line
Flap discs 3 61 Product lines For craftsmen or industrial use - three precisely coordinated product lines offer the right flap disc for every user and every application. All discs comply with the relevant
MF9254 ADVANCES IN CASTING AND WELDING PROCESSES UNIT III RECENT TRENDS IN CASTING AND FOUNDRY LAYOUT
MF9254 ADVANCES IN CASTING AND WELDING PROCESSES UNIT III RECENT TRENDS IN CASTING AND FOUNDRY LAYOUT Syllabus Shell moulding, precision investment casting, CO2 moulding, centrifugal casting, Die casting,
A critical review on sand casting technology
A critical review on sand casting technology DR. T.R. VIJAYARAM Prof., SMBS VIT University S and casting technology also known as sand molded casting process. It is a metal casting process characterized
Investment Casting with FDM Patterns
TECHNICAL APPLICATION GUIDE Investment Casting with FDM Patterns Investment casting produces ferrous and non-ferrous metal parts with excellent surface finish and dimensional accuracy. This manufacturing
Influence of pressure mould material on the durability of coating a thermal and anti-erosion barrier
ARCHIVES of FOUNDRY ENGINEERING Published quarterly as the organ of the Foundry Commission of the Polish Academy of Sciences ISSN (1897-3310) Volume 9 Issue 2/2009 113-118 26/2 Influence of pressure mould
Metal Casting Dr. D. B. Karunakar Department of Mechanical and Industrial Engineering Indian Institute of Technology, Roorkee
Metal Casting Dr. D. B. Karunakar Department of Mechanical and Industrial Engineering Indian Institute of Technology, Roorkee Module - 02 Sand Casting Process Lecture 03 Moulding Sands and Design-II Welcome
SRI RANGANATHAR INDUSTRIES SAND CASTINGS SRI RANGANATHAR VALVES SAND CASTINGS AND INDUSTRIAL VALVES
SRI RANGANATHAR INDUSTRIES SAND CASTINGS SRI RANGANATHAR VALVES SAND CASTINGS AND INDUSTRIAL VALVES SRI RANGANATHAR VALVES & CONTROL PVT LIMITED INVESTMENT CASTINGS BRAIN BEHIND THE FIRST GENERATION Mr.
Mid term Review Questions P a g e 1 CASTING
Mid term Review Questions P a g e 1 Q1: Define the casting process? CASTING A1: Casting is the process of pouring molten metal into a mould containing a cavity, which represents the required product shape