2. Lost Wax/Invest Process History stretches backward
beyond the Egypt’s Pyramids/ China / Dwaper Yug of
lord Krishna in Artisana and High precision ,Precious
and artistic Jewelry & Gold Ornament manufacturing
Which remain most popular technique today also . . . .
After Dark Ages,Ebullient sculptor & Gold Founder
(1766 B C) Benevenuo Cellini claim fascinating
autobiography How he make use of “ Lost Wax “
which he learned from a description by the Monk
Thophilus Presbyter ( circa 1100)
Creating Original artistic work on wax model,Coating
with milky slurry,forming strong shell by successive
coats,melting out wax and pouring a molten gold/silver.
World War II had Ignited development of this process due to
sudden huge requirements of Aircraft /Military/ Automobile
/ammunition parts mfg which eliminate machining-welding-assembly
with high dimensional accuracy ,finish of complex geometry parts.
3. * Casting Limitation 2.0 Gms to 45 Kilograms per Piece
* Casting size 2 Cu mm to 610 Cu mm in size
* Minimum Casting Wall thickness 1. 0 To 1.5 mm
* Casting Surface finish 1.6/3.2 Micron /80-125 RMS
* Delivery Minimum . . . . . .
* Dimensional Accuracy
>Normal/ +/- 0.2 mm up to 25 mm &+/- 0.1 with each
additional 25 mm thereafter
>Premium/Coined +/- 0.15 mm up to 25 mm &+/- 0.08
with each additional 25 mm thereafter
* Tolerance VDG-Markblatt P690 class D1 spec
IS -11166-1994
* Die Tool Manufacturing Accuracy +/- 50 Micron &
Die Tool Assembly Accuracy +/- 50 Micron
Preferable Tooling Manufacturing on CNC.
Harshukh Bhatti
Director,
Trauma Engineering Services.
8 to 12 week
4. investment / lost wax casting process
1 Wax pattern Injection
2 Ejection Wax Pattern 1 2 3
3 Cluster Assembly with
casting Methoding.
4 Investing cluster or tree 4 5 6
5 Stucco,Reinforcing Coats
6 Shell Drying
7 De wax the shell mold
8 Firing the shell 7 8 9
9 Metal Pouring
10 Knock out & Fattling
11 Casting finishing 10 11
5. Stereolithography
Stereolithography accurate and
functional components for the philosophy
of “ Test by Design ” base d on the I-
DEAS 3D Modelling Software.
A highly accurate components are built up
in layers as fine as 0.1 mm helping to
ensure highest accuracy,as well as
minimizing finishing time by SL 5195 resin
specifically formulated by
CIBA Chemicals. The basic resins are
Poly Urethane is a technique to produce
extremely which have excellent
component mechanical strength
and good optical clarity, which
proved as best prototype pilot
model for development.
BOING 777 is first world best Craft,
100 % Design by 3D solid Modelling on the
Globe. The Design Logic was
“Working Together”
6. 3D Solid Modelling for Vane Development
of Suction & Pressure
side of vane
10. Diffuser CNC Wax
Die Tool
At bottom Actual
Component
Segment Die Tool for
Pres/Suc vane of Impeller
Water Soluble segment Core
Soluble core disolve in
water flow and form a
cavity of an Impeller
11. IDP & IR
DIE TOOLS FOR water
soluble segment core of close
Impeller for Internal cavity at
IPCL TOOL ROOM .
All the Die Tools are
manufactured on CNC
Milling with a acuuracy
of +/- 0.001” and assly tole
of +/- 0.002 / 0.003“.
Die manufacturing stages:
Die Design 3 D Modelling Die
Split line Die Construction
Compound Die Insert
Die Cooling Wax Pattern
Injection - Ejection Devices
Comp’t Volume measurement
Weight Control On
“IDEAS & MASTER CAM”
software
12. Open Impeller
DIE Tool
Cost 1.35 Lac
WAX Pattern
with Wax +
tool + Metal
Contraction
9 # Vane
Incert Die
Tools
425 mm
Component
Diameter
13. Soluble segment core are placed
in Impeller housing Wax Die for
WAX Injection.
Soluble wax & WAX pattern are
kept in flowing water which
dissolve soluble wax & causing
cavity in the Impeller wax
pattern thus forming vanes of an
impeller.
WAX Injection Press
for Making wax patterns at
press. Of 3 to 4 kg/cm2
Specially blended
Industrial Wax
14. Mr Carlo Grossi & Mr Subramaniam
On process presentation for
Investment & Ceramic Precision
casting Production.
Under control temperature
18*C & Control rel Humidity.
Ceramic Injection press for
making extra high Strength Core
to withstand high buoyancy
draught, Core lift ,Increase high
temp. Core permeability and
better Dimensional Control in
Ceramic casting. Core segments
are pasted to complete circular
cavity.
15. Wax Patterns Ready for
Gating system and Methoding
TREE MAKING
Ingates & Risers
Venting Provisions
Chills/Chaplets provisions
Core supports (by pasting
wax rods).
Metal Yield 25 % to 35 %
16. IMPELLER WAX PATTERN
Under Control Temperature
ready with all Methoding
requirements by
Design /Method Dept.
WAX Pattern Tree ready for
PRIME SHELL COAT
17. This image cannot currently be displayed.This image cannot currently be displayed.
Prime Shell Coat
Reinforcing Coats
Silca Bonding --
buble Pan -Air strem
from Bottam
18. Prime Shell Coating
•Finish
•Bonding
•Adhesion to pattern
•Refractory Quality
•Zircon base
•Flowability & Intricacy.
•Sharpness & clarity.
•Reinforcing of shell.
Secondary Shelling
Coats . . . . . .
Quartz silica
Colloidal silica
Bonding Agents
Reinforcing Coats
Glass Wool Mat
under control temp.
CORE LIFT CONTROL
Reinforcing Media
Ceramic sec”X I 0 Z ”
Hollow Section inside
the cores 8 to 12
Coat
Minimum 8/10 Hrs dry
Extra strengthening of
shell to prevent
bulging & ballooning
19. Intricacy
In as cast condition 0.15mm Clearence
bet’n outer Guide raw and 1st raw lug
Lost wax
Features
Keyway
4 mm hole
1 mm slitting
Orientation
Bore within 0.1
OD 110 mm
Weight 1.63 kg
Finish 95 rms
Balancing accu-
racy
+/- 5 gms/inch
20. Ceramic Segments Assembly
Gravity Cast
Centrifugal Cast Core
Injected Casted Core
Reinforcing Core by
I,Z,X,O,H Section inside
the core for restricting
Bowing / lifting of Core.
Core assembled,locked,pasted and precured
Core repairs,
Core Locking
Core placment
Sealing Cop/Drag assembly
Joint Sealing / pasting / precuring
21. DEWAXing Chamber / Pits
Wet Dewaxing InHOT Molten
waxpit
Dewaxing by Super sature.Steam
Dry dewaxing by soaking the tree
in inverted position and thus
cavity formed.Melted Wax is
drained away.
Dewaxed Shell hollow from
Inside and Ready for Firing
/Curing.
22. Hot metal metallurgical Charge
Under preparation. . . . . .
Ferrous Metal charges for required
alloying elements+Oxidiser
Control Metallurgy-Spectroanalysis
Awaiting Tapping signal from
chargman / Metallurgist
FIRING of SHELL
Dewaxed shell at 810*C
Residual wax to burnt
Glasswool protection
Reinforcing application
Soak-time~Shell Volume
Fragile Handling of Shell
Shell Pouring BED
Deoxidiser
Masking of Shell
23.
24. Shell-bed & Pouring
810*C fired shell on sand bed
Proper seat on bed to absorb
metal dropping while Metal Pour
Crucible metal to hot fired
shell ,Prevent shell puncturing
Prevent Oxidation by Flux ,
Atmospheric Shied by Covering
poured shell with help of blind
drum with deadweight on top.
26. Mr Bhatti & Mr Grossi on Shop
visit Casting inspection / heat-treatment
warp & Torn casting.
COINING Operation for Premium Casting
Restoring Dimension Loss in HT
Restoring Geometry Loss in HT
Restoring Size & Shape loss in Handling
.
Induction Hardening
Automotive Industrial products like
Gearbox forks tips at 58/60 Rc
Special holding Fixture for com’t
Specially shaped HF Induction coil
for every component.
28. Shell Breaking hammers &
Tree Cutting
Fused ceramic of shell are braked
off by pneumatic hammers
Components are separated from
cluster/tree by Gas cutter , Sawing ,
Plasma cutter,Diamond Cutters.
Hollow Comp’t Internal passages
are cleaned by Leaching, Hot
NaOH solution for 48 Hrs
Dissolving Silica
Hollow Components like Impellers
Mr Grossi Verifying Any Fins, Blockage and Obstructions in
the Impeller Vane Cavity.
Core Lift/Core Breakage, Ballooning
restricting the Hydraulic passages & performance
Challenging obstruction & defects.
Strictly not Acceptable
Metal lumps/fins/obstruction to be removed by Specially
designed Curved Tooling & grinder - access remove any
irregularities of the passages.
Special tooling For Vane Obstruction Removal
30. Impellers Under Metal
Cleaning Process
Shot Blasting Steel / SS
Sand Blasting
Acid Cleaning
Hot NaOH Leaching
Wire Brushing
Stretch Filing & fit-ups
31. Final Designing final Quality Control measures of components
Pre-Tooling Inspection Cad /Cam/tool Insp/Tool assly Insp/wax pattern trial
Dimensional Inspection confirming Drawing requirements + Geometrical tole
Physical Testing UTS/YP/YS/I Impact test/Hardness
Metallurgical Requirements as per customer’s standards/Microscopic exam ’n
Non Destructive testing DP,UT,MPT,RT, VI & Compliance of API
Hydraulic Testing of Pressure tight Components
Commercial Verification Weight Analysis and S Q C Control
Ascertaining Convention Quality Check
32. Impeller 100% Machining all Over with Six Axis Machining Center
Vane Inlet Tip thickness 1.5mm and Bottom Raddi if 1.5mm
Impeller Rotating Speed 20Krpm to 70Krpm
Rotor assembly-Salvation & Restoration, Rework Dynamic Balancing
And
Restoring to design functionality of High Speed turbo machines
With forecasted Capacity or Energy Loss
As Interim FIX.
3D Modelling
CAD / CAM
Programming
3- Axis
5-Axis
Marching
NDT Compliance
API Compliance
Over speed Test
Bursting Test
33. 5 & 6 Axis Machining of Guide Vane and Diffuser
Machining Accurany 25 Micron
