DIE MOULD/MAKING :

From using 2D drawing of investment casting provided by customer, we manufacture die (pattern/tools) of Aluminum material using CAD/CAM. We send drawing to customer for approval making appropriate changes in drawing based on lost wax casting process requirement. We technically support our customers for developing cost effective product based on material/machining cost savings.

WAX INJECTION:

Wax in semi-liquid form is injected in Dies (Pattern/Tools) to produce replica of desired castings. Semi automatic hydraulic press is used to produce wax patterns. All the wax patterns are 100% checked visually and dimensionally.

WAX PATTERN PROCESSING:

Wax in semi-liquid form is injected in Dies (Pattern/Tools) to produce replica of desired castings. Semi automatic hydraulic press is used to produce wax patterns. All the wax patterns are 100% checked visually and dimensionally. Wax patterns are assembled to wax runner using wax gates and then wax runner is attached to wax pouring cup to make a cluster or tree.

WAX ASSEMBLY

Wax patterns are assembled to wax runner using wax gates and then wax runner is attached to wax pouring cup to make a cluster or tree

SHELLING:

The wax assembly is coated with a ceramic shell by repeated dipping in ceramic slurries and alternately in dry beds of sand and clays, heavy or thick sections are features of any part, additional coating are to give added strength to the shell. Thus eliminating bulging or distortion of the casting to complete this stage, the ceramic shell is heated under pressure in an autoclave and the wax removed by melting, leaving a hollow shell.

SHELLING:

The most crucial stage of the shelling process is the primary coating, where a very fine grade of sand is used. This in turn results in a casting with excellent reproduction detail and the designated surface finish.

MELTING :

The shell is then subjected to preheating to remove moisture and residual wax, and to sinter the ceramic of shell. The specified alloy, melted in induction furnace, is poured into sintered shells and then shells are left to solidify molten metal.

HEAT TREATMENT :

We have in-house heat treatment furnace with rapid quenching facility. Furnace is calibrated as per API 6D and there is systemized control for real time temperature of different zones.

FETTLING & FINISHING:

After cooling, ceramic shells are removed through mechanical vibrating, water jet or media blasting. Finally castings are separated from cluster through cut-off through abrasive wheel or weld cutting. Then heat treatment, finishing and final inspection are carried out.