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Investment casting, also known as lost wax casting, is a precision metal forming process that is widely used to manufacture parts with complex shapes and high precision requirements. This casting method uses a series of complex processes to wrap a pattern (investment pattern) made of fusible material in a mold shell made of multi-layer refractory materials, then melt the pattern and discharge the mold shell, and finally pour molten metal into it. Cool and form. So,what are the materials used in investment casting?Next, the LS team will take you to an in-depth discussion of the performance characteristics, scope of application and selection principles of each material, hoping to help readers make more informed decisions in material selection for investment casting.

What Materials Are Used in Investment Casting?

Investment casting mainly uses the following types of materials:

1.Investment materials

Investment moldis a key part in investment casting, which determines the shape and dimensional accuracy of the final casting. Investment mold materials are usually divided into two categories: wax-based mold materials and resin-based mold materials, of which wax-based mold materials are the most commonly used.
Wax-based molding materials: Wax-based molding materials are mainly composed of various wax materials, such as paraffin wax, microcrystalline wax, Fischer-Tropsch wax, polyethylene wax, etc. These waxy materials have low melting points and are easy to shape and demold. In addition, various additives can be added to thewax-based molding material, such as polyethylene, ethyl cellulose, etc., to improve its strength and toughness.

2.Resin-based molding materials

Resin-based molding materials are mainly made of natural resin or synthetic resin, and their melting points are relatively high. Resin-based molding materials are usually used in situations that require higher investment quality, such as higher dimensional accuracy and surface finish.

3.Refractory material

the main component of the mold shell. Commonly used materials include mullite sand, mullite powder, quartz sand, etc. These materials have excellent high temperature resistance and chemical stability, and can withstand the high temperature and pressure of molten metal.
Binder: used to bind refractory material particles together to form a strong shell. Commonly used binders include various resins, cement, water glass, etc.

4.Molten metal

Themetal materialthat is finally filled in the mold shell can be stainless steel, carbon steel, alloy steel, heat-resistant alloy, copper alloy, aluminum alloy, etc.

What Metals Are Commonly Used in Investment Casting?

Investment casting is a precision casting process capable of producing metal castings with complex shapes and high precision. In investment casting, commonly used metal materials mainly include aluminum, stainless steel, titanium and various alloys. Here’s a detailed analysis of these metals:

• Stainless steel:Compared to many other materials,stainless steel stands out for its exceptional durability, a quality that has prompted designers and engineers to increasingly turn to investment casting technology. Stainless steel is used in a wide range of applications, including transmission components and various gears in the automotive field, as well as camping equipment and golf club heads.
• Low alloy steel:Low alloy steeloccupies a pivotal position in the machinery manufacturing industry due to its affordable price and excellent mechanical properties. Through specific heat treatment processes, engineers can engineer different areas of the same workpiece to achieve differentiated performance, for example, making one surface tough and impact-resistant while another surface offers excellent wear resistance.
• Aluminum alloy:Aluminum alloy is the favorite in the field of investment casting, especially in aerospace, avionics, electronic equipment and military industries. With the continuous improvement of material strength and the popularity of high-quality aluminum-silicon-magnesium alloy castings, aluminum alloy castings can now meet the needs of demanding applications such as fuselage components.
• Carbon steel:As a low-cost and common material,carbon steel comes in various types, mainly classified according to carbon content. Through heat treatment, the strength, ductility and overall performance of carbon steel can be significantly improved. The ferromagnetic properties of carbon steel make it suitable for motor and electrical appliance manufacturing. Carbon steel has become one of the most commonly used alloys worldwide due to its safety, durability and excellent structural integrity.
• Super alloy:Nickel-and cobalt-based superalloys play an integral role in the aerospace, energy, medical, chemical and marine industries. Nickel-based alloys perform well in high-temperature environments, while cobalt-based alloys are superior in corrosion, oxidation and wear resistance. As superalloys gradually replace sheet metal, their high stiffness, excellent service characteristics and cost-effectiveness are becoming increasingly popular.
• Copper alloy:Copper-based alloys are known for their excellent corrosion resistance and low wear rate, and are widely used in ship propellers, pump propellers, electrical components, and pipeline components. As a versatile material, copper alloys come in more than 400 different varieties, each with its own characteristics.Investment casting technologycan be used to manufacture a variety of copper-based alloy parts, among which bronze and brass are the most common. Beryllium copper is one of the strongest copper alloys, its performance is comparable to high-strength alloy steel, and it also has stronger corrosion resistance and longer service life.
• Cast iron:Cast iron, especially gray iron and ductile iron, is known for its high precision and affordable price. Ductile iron not only has high strength, heat resistance and toughness, but its production process is also relatively complex, resulting in production costs that are slightly higher than cast steel.

What Non-Metallic Materials Are Used in Investment Casting?

Investment casting technology is a high-precision casting method, which not only relies on metallic materials, but also requires a variety of non-metallic materials to complete the entire casting process. With the development of modern science and technology and the increasing requirements for product performance, non-metallic materials play a pivotal role in investment casting. The following is a list of non-metallic materials that are often used in theinvestment casting process:

1.Waxy substances:

• Application Scenario:In the investment casting process, wax is mainly used as a base material for building mold patterns. Since wax is made up of wax, wax patterns are also known as wax types. Using pressing or3D printing, we are able to create wax patterns that match the appearance of the desired casting.
• Features:Wax is considered the material of choice for complex moldsdue to its excellent plasticity, ease of processing and suitable melting temperature. Therefore, wax molds are widely used in the casting industry, especially cavities made of wax for large precision iron castings and thin-walled parts. In addition, the wax's ability to leave no residue during the complete melting process is crucial to ensuring dimensional accuracy and surface quality of the casting.

2.Ceramic products:

• Uses:In the investment casting process,ceramics are used to make shell molds, also known as shells. The mold consists of a casing with at least one layer of ceramic material. This shell mold provides the high-temperature resistance and structural integrity required for the injection and cooling of molten metal.
• Features:This ceramic material has a high melting point, excellent thermal stability and chemical stability. This performance allows it to manufacture molds with a variety of complex shapes that differ from many traditional methods. In the process of investment casting, the surface of the wax mold is covered with a ceramic slurry and undergoes a series of drying and sintering steps to form a stable shell. This ceramic housing is obtained by mixing metal powder with a binder. The enclosure has the ability to withstand the pouring of hot metal melt and retains its original shape and structural integrity after cooling.

What are the benefits of investment casting?

Investment casting offers many advantages, including:

1. High precision:This method allows for tight tolerances and fine geometries that are often difficult to achieve with other casting techniques. The precision of lost wax casting makes it ideal for components requiring high precision and finesse.
2. Versatility:Works on a variety of metals and alloys, including ferrous and non-ferrous metals. This versatility allows manufacturers to select the best material for their specific application.
3. Smooth surface finish:This process produces parts with excellent surface quality, reducing the need for extensive machining or finishing work. This reduces overall production costs and improves aesthetics.
4. Reduced machining:Investment casting minimizes the need for secondary machining operations because the parts come out of the mold very close to final dimensions. This not only saves time but also reduces material waste.
5. Design flexibility:Lost wax casting enables complex designs that are difficult or impossible to achieve with other casting methods. This flexibility enables engineers to create innovative solutions that meet specific performance requirements.

What Are the Applications of Investment Casting?

Investment casting plays a vital role in numerous industriesdue to its high flexibility and unparalleled precision. Here are some examples of particularly prominent application areas:

• Aerospace field:Investment casting technology can achieve very high dimensional accuracy and surface finish, and is especially suitable for producing castings with complex shapes and high precision requirements.In the aerospace field, it is widely used in the manufacture of key components such as engine blades and turbine disks.These parts have extremely high requirements for dimensional accuracy and surface quality, and investment casting technology can meet these needs and ensure the performance and reliability of the parts.
• Automobile manufacturing field:In the automobile manufacturing field,investment casting technologyis used to manufacture complex-shaped parts, such as engine blocks, steering gears, etc. These parts also have high requirements for precision and surface quality. Investment casting technology can provide high-quality, high-precision castings, thereby improving the performance and reliability of automobiles.
• Medical device manufacturing:In the medical field,investment casting technology is also used to manufacture delicate medical devicesand implants. These medical devices and implants have extremely high requirements for dimensional accuracy and surface finish to ensure their safety and effectiveness during use. Investment casting technology can meet these needs and provide high-quality, high-precision castings for medical device manufacturing.

Cooperate with LS for investment casting project

Investment casting is a great metal forming process. It is a tried, tested and proven method that helps achieve lean, high-quality production. Not only is it a cost-effective way to produce custom metal parts and components, but it also allows you to create complex net shapes and complex internal features. Choosing the right investment casting company is very important,
If you are interested in learning more about our investment casting services,please contact usfor a free quote on your project.

FAQs

1. What types of materials are mainly used to make the molds?

The core of melt mold casting is the use of perishable materials (usually waxy materials) to make molds, called wax molds. These wax molds undergo subsequent treatment, such as coating and roasting, to eventually become type shells that can place the metal. In addition to wax materials, natural resins and plastics (synthetic resins) can also be used to make molds, but they are relatively rarely used.

2. What is the coating material of the wax mold?

In order to protect the wax mold and form a solid shell after melting, apply several layers of refractory material on the wax mold surface. These materials usually include a variety of refractory powders, such as Murray sand and powder, which maintain stability at high temperatures to prevent the metal melt from penetrating and support the shape of the casting.

3. What types of alloy casting can be produced by melt mold casting?
melt mold casting has a wide range of alloy applicability, can produce carbon steel, alloy steel, heat resistant alloy, stainless steel, precision alloy, permanent magnet alloy, bearing alloy, copper alloy, aluminum alloy, aluminum alloy, titanium alloy and ductile iron and other alloy casting. These alloys have different mechanical and chemical properties for various application scenarios.

4. What are the commonly used classification agents when making wax molds?
Classification agent is used to prevent adhesion between the mold and the wax mold when pressing the wax mold. For wax-based molds, commonly used typing agents include oil and turpentine, and for resin-based molds, sesame oil and alcohol mixture or silicone oil are commonly used as typing agent. The selection and use of these typing agents is essential for obtaining high-quality wax molds.

Summary

Investment casting plays an important role in modern manufacturingwith its high precision, complex shape production capabilities, and wide material applicability. By precisely controlling each process step, investment casting can produce high-quality castings that meet the needs of various complex application scenarios.

Disclaimer

The content on this page is for reference only.LSdoes not make any express or implied representation or warranty as to the accuracy, completeness or validity of the information. No performance parameters, geometric tolerances, specific design features, material quality and type or workmanship should be inferred as to what a third party supplier or manufacturer will deliver through the Longsheng Network. It is the responsibility of the buyerseeking a quote for partsto determine the specific requirements for those parts.Pleasecontact usfor moreinformation.

LS Team

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Resource

https://en.wikipedia.org/wiki/Investment_casting