Investment casting shell removal

Investment casting shell removal

Accelerating Precision Casting At its core, the investment casting process is simple: create a model, form a mold, pour the metal. At most traditional precision metal foundries, you then wait anywhere from 6 to 8 weeks or more to get your part. We call this Continuous Flow, and with our innovative processes and advanced automation, it can get you from design to delivery in 10 steps—often even under 10 days. This means you get all the benefits of one of the most flexible and repeatable precision metal processes in history, along with delivery of your components faster than any other investment caster, all at a lower total cost.

investment casting shell removal

Skip navigation. Contact Request A Quote Locations. Request a Quote. Ask An Engineer. Request A Seminar. Any part, any volume, any level of complexity—accelerated. Precision where it matters most. All rights reserved Last updated Automated to produce patterns efficiently and provide dimensionally consistent patterns.

Injects semi-solid wax using an automated process developed in-house for higher dimensional stability. Using robotics helps us shave more than five days off the shell-building process alone vs traditional foundries. The high temperature we use to melt out the wax improves the feed of liquid metal and the fine detail of the cast. Robotics-assisted pouring allows us to reach ultra-high temperatures, with spectrographic analysis to meet specs.

A proprietary process removes castings, while shell removal is done with high-pressure water jets and a hot chemical bath. Treatments and services that all work hand in hand with our modules to make your part ready for assembly.Ceramic shells are typically chipped away from investment castings, a process that is not only tedious and labor-intensive, but can damage the casting inside.

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The more intricate the casting shape, the bigger the problem. NLB high-pressure water jets cut cleanly through the hard ceramic but leave the casting unscathed. Typically, precision nozzles are mounted on a robotic arm or hand lance, providing more thorough coverage and significantly higher productivity. Learn more about using water jets to remove casting material. Learn More Electric units Electric pump units are commonly used for in-plant applications. Anti-Corruption Guidelines.

Problem: Ceramic shells are typically chipped away from investment castings, a process that is not only tedious and labor-intensive, but can damage the casting inside.

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Solution: NLB high-pressure water jets cut cleanly through the hard ceramic but leave the casting unscathed. Advantages: Complete shell removal in minutes No damage to valuable castings Can be manual or automated Easier on personnel Standard cabinets available. Product removal brochure Learn more about using water jets to remove casting material.

Learn More. Electric units Electric pump units are commonly used for in-plant applications. About Our Story News Events. Online Inquiry. We and the third parties that provide content, functionality, or business services on our website may use cookies to collect information about your browsing activities in order to provide you with more relevant content and promotional materials, on and off the website, and help us understand your interests and improve the website.The investment casting process begins with production of a heat disposable pattern.

KMT Robotic Solutions leads the way in investment casting shell and core removal

This pattern is usually made by injecting molten wax or plastic into a metal die or mold. The wax patterns are attached by the gate to a central wax runner system.

The runner system is called a sprue. Patterns, runners, and pouring cup comprise the cluster or tree. The shell building technique involves dipping the assembly into a ceramic slurry and then into a bed of extremely fine sand.

investment casting shell removal

After drying, the process is repeated. Up to 7 layers may be applied in this manner. The completed shell is placed in a steam autoclave where the pattern melts and runs out through the gates and pouring cup. The ceramic shell molds must be fired to burn out the last traces of pattern material and to preheat the mold in preparation for casting, usually in the range of degrees Fahrenheit.

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The preheated shell is filled with molten metal by gravity pouring. As the metal cools, the parts, gates, sprue, and pouring cup become one solid investment casting. After the metal solidifies and cools, the ceramic shell is then removed by vibratory methods or water blasting.

Individual investment castings are removed from the cluster by friction sawing or by means of a cut off wheel. Remaining gate protrusions on the investment castings are removed by belt grinding. The investment casting process is now complete. Finished investment casting parts are now ready for heat treating and shipping to customer. The following procedures are typical of the investment casting process. Wax Injection The investment casting process begins with production of a heat disposable pattern.There are many methods of removing Investment Casting shell and insulation; these methods include impact, shot blasting, grit blasting and manual waterjetting.

There are two programmable spindles, an indexing spindle system that allows loading during processing. A Fanuc, industrial robot moves the rotating nozzle over the surface, pausing in positions that require more attention.

The ceramic shell breaks away in large pieces at the start of the process and down to granular, sand-like material at the end of the cycle. The cabinet needs to reclaim and contain this large range of debris. The cabinet has an automated washdown to clean the ceramic material.

Standard Stainless Steel cabinet with waterproof lighting and windows. Cabinet washdown and floor protection covers Fanuc Robot with Rotating Nozzle system Two part spindles with part hold downs and fixture mounts Mist Collector to remove airborne water vapor from exhaust air 80 dBA sound level, lase part alignment and two handed index controls.

Tell us about your application. Systems Pro selector. Customer services Process services. Follow Progressive. Toggle navigation. What is grit blasting? What is thermal spraying? What is waterjet cleaning? This Robotic Waterjet uses a high pressure pump 20ksi pressure and rotating nozzle system. This system increases output, reduces operator fatigue and provides a quiet plant environment.

Cabinet washdown and floor protection covers Fanuc Robot with Rotating Nozzle system Two part spindles with part hold downs and fixture mounts Mist Collector to remove airborne water vapor from exhaust air 80 dBA sound level, lase part alignment and two handed index controls Optional PRIMS Pro Operating and Monitoring System Water filtration and shell removal Roboot washdown nozzles at each robot joint Part holding fixtures and production ready programs Our machines meet your application-specific needs, Procisely.

Tell us about your application Related videos.A method of improving the removal of an investment casting shell surrounding a metallic article. The shell is made from the deposit of layers refractory slurry and stucco onto a pattern. The shell contains, after firing, an amount of an alkali metal oxide or an alkaline earth metal oxide sufficient to reduce the strength of the shell.

investment casting shell removal

By this invention, after firing of the shell and pouring of the molten metallic part into the shell, the shell is hydrated to further reduce the strength of the shell, to facilitate its removal from the metallic part.

Share Patent Tools. The method of claim 1 in which said refractory material comprises fused silica. The method of claim 1 in which said refractory material comprises aluminosilicate. The method of claim 1 in which said refractory material comprises zircon. The method of claim 1 in which said first average grain size is mesh.

The method of claim 6 in which said refractory material is fused silica and the first average grain size is mesh. The method of claim 8 in which said refractory material comprises fused silica and the first average grain size is mesh. Owners US.

Waterjet cleaning

Explore more patents:. CPC Classifications. IPC Classifications. US Classifications. US B2. US A. Cancel Download.

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Sign in to the Lens Email address or Username. Keep me logged in. Sign in. Forgot Password? Register New Account.From molds for small candy-coated chocolate morsels to jet engine turbine blades, from a few grams to several thousand pounds, the process provides millions of castings that meet everyday practical needs.

Wax shrinkage, refractory shrinkage and alloy shrinkage are all factors considered when cutting the die cavity. A tree can consists of one wax part, or in some cases, hundreds of wax parts. With very few exceptions, the ceramic shell has replaced the solid mold method of investing the wax assembly.

This is accomplished by dipping the wax assembly or tree into a ceramic slurry followed immediately by a coating stucco of dry refractory grain. The composition of the slurry and refractory grain is selected primarily based upon the alloys cast. The coated assembly is then allowed to dry in a controlled environment. The dip, stucco and dry steps are repeated until a shell of sufficient thickness has been formed.

Since investment shells are cast unsupported, it is also necessary to have a fired strength capable of holding the weight of the metal cast, another consideration for determining the shell thickness. When the shell is complete, it is necessary to remove the wax invested within. This is accomplished by either placing the shell into a steam autoclave or directly into a preheated furnace. To minimize shell cracks from wax expansion, it absolutely necessary to reach de-wax temperature in a very few seconds.

As the wax melts it exits the shell through the runner or sprue system of the assembly. After de-wax, the shells can be stored in an uncontrolled environment until scheduled to cast. Prior to casting the shell is fired primarily to develop the fired strength of the ceramic green or unfired shells have insufficient strength to contain the metaland secondarily to remove any traces of the wax. After proper firing, the shells are removed from the furnace and immediately cast unsupported.

The metal enters the shell through the runner or sprue system, which must be of proper design to prevent metallurgical defects due to improper gating. Because of metal shrinkage during solidification much of the ceramic shell literally falls off the castings; however, additional cleaning is required to remove all the shell material.

Following initial shell removal, the individual castings are removed from the gating system by some means of metal cutting. Vulcan Engineering Co.

investment casting shell removal

We also supply completely engineered drying systems, both horizontal and vertical cabinets with and without de-humidification and complete shell management software. Vulcan Engineering offers the best quality equipment and complete systems in the industry for investment castings.

Investment Casting Process. Although the process is ancient in origin we can attribute the success of some of our modern technical advances to the process. Click Here for location information and international phone numbers.

News Found out about the latest products, technology, and trade events we are involved in. Click Here.Magnus Engineered Equipment MEE has supplied equipment to the investment casting industry for more than 50 years.

Investment casting, or die casting, is a technique for forming metallic components having complex geometries, especially hollow components. Hollow cored super alloy airfoils and gas turbine engine components are examples of complex geometries produced with the investment casting process. MEE equipment is used with concentrated caustic solutions of NaOH sodium hydroxide or KOH potassium hydroxide to remove shell residues from ferrous and non-ferrous metal castings including aluminum.

Operating at just below the boiling point of the solution, the process breaks down the fused silica shell used in the investment casting process without damaging the metallic substrate. The process is faster, safer and more efficient than mechanical methods of shell removal and all surfaces within the substrate are cleaned.

MEE supplies equipment which uses heat, agitation and turbulation to quickly and effectively remove the shell residues from substrates including the complex geometries found in many castings. The effect of agitation and turbulation increases the dissolution rate by increasing chemical mass transfer at the shell interface.

Agitation and turbulation act to quickly remove dissolved silica and spent chemistry from the substrate surface while bringing in fresh chemistry to continue the dissolution reaction at the fastest rate.

MEE supplied equipment also continuously filters the bath thus removing dissolved silica and enhancing the dissolution rate of the remaining ceramic shell by returning clean chemistry to the part surface. As a rule of thumb, it is advisable to operate at a temperature which is 20 oF below the boiling point of the solution being used so as to prevent cavitation in the pumps used to circulate the solution. The lower pressure on the suction side of the pump lowers the boiling point of the solution.

Ceramic Shell & Core Removal

MEE supplies off-the-shelf or custom designed equipment for investment casting removal applications. Material handling, by-product removal, automation and post-processing needs can be addressed by MEE to make the overall process efficient and worry-free.

Contact MEE today to discuss your investment casting application.

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May it hurt the part itself? Great question, Mahtab! This is what our IC tanks do. Our tanks are constructed from stainless steel so the parts should remain unharmed. Your email address will not be published.

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Investment Casting Animation

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