Investment Casting

Custom Investment Casting Services

JIAHUI is your one-stop solution for investment casting process services. We specialize in lost-wax casting, an exact manufacturing process that allows us to create metal parts with intricate geometries and fine surface finishes. Our expert engineers utilize the latest technology and techniques to produce custom patterns and molds, ensuring the highest accuracy and consistency in each casting. With our extensive capabilities, rigorous quality control measures, and efficient production processes, we can meet the unique needs of various industries, including aerospace, defense, automotive, and medical.

  • Precision casting
  • Customizable solutions
  • Efficient production processes
Investment Casting - https://jiahuicustom.com/

What’s Investment Casting Process?

Investment casting is a manufacturing technique that produces high-precision and quality complex metal parts. The process entails the formation of a wax pattern for the desired component, which is then covered with a ceramic material. Subsequently, the assembly is subjected to high temperatures to eliminate the wax and solidify the ceramic shell. Molten metal is then introduced into the shell and allowed to harden, forming the final part.

Investing casting is typical for fabricating components featuring complex geometries, delicate walls, and precise tolerances that would prove challenging, if not impossible, to manufacture using alternative production techniques.

Investment casting’s primary benefit lies in its capacity to manufacture components with exceptional surface finish and accuracy. The process can also have parts with minimal material waste and can be used to create components in various materials, including steel, aluminum, and titanium.

The investment casting process requires high upfront costs to create the wax patterns and ceramic shells, which can be time-consuming. However, investment casting can provide a cost-effective solution for high-precision and quality applications.

Our Qualification for Investment Casting Service

JIAHUI provides investment casting services using advanced technology and techniques to create high-quality, precise, accurate, cost-effective parts.

Our experienced technicians work closely with clients to select the best project materials, surface treatments, and tolerances. We offer guidance and solutions throughout the investment casting process, from material selection to delivery. Our professional management team ensures clients can track their orders at every production stage and receive their parts on time and within budget.

Whether for aerospace, medical, or other industries, our investment casting services can help clients achieve the highest precision and accuracy. We are dedicated to delivering high-quality parts that meet our customer’s conditions and exceed their expectations.

Manufacturing Process

Our services employ advanced techniques, using wax or plastic patterns encased in ceramic shells. Molten metal replaces the pattern, resulting in flawless replicas. With material versatility and meticulous attention, our investment casting creates components that marry precision and durability.

Material Weight Size Limit Surface Finish Wall Thickness (Min)
Steel 20g-50kg 500mmx500mmx500mm Ra 6.3µm (3.2µm achievable if specified) 1.0mm
Aluminum 20g-10kg 300mmx300mmx300mm Ra 6.3µm 0.6mm
Copper 20g-10kg 500mmx500mmx500mm Ra 6.3µm 0.6mm
Inconel 10g-10kg 300mmx300mmx300mm Ra 6.3µm 0.6mm

Our Investment Casting production Capabilities

From design to production, JIAHUI showcases capabilities that blend artistry and innovation, shaping components that testify to modern manufacturing prowess.

Materials for Investment Casting Parts

Ultimately, the investment casting process seamlessly accommodates an array of materials. From robust stainless and carbon steels to high-performance superalloys like Inconel and ductile iron, each material choice is driven by strength, heat resistance, and corrosion resilience.

  • Stainless Steel
  • Alloy Steel
  • Carbon Steel
  • Aluminum
  • Copper
  • Ductile Iron
  • Inconel

Stainless Steel

Stainless Steel

Stainless steel is metal-enriched with chromium elements (11%) and a small amount of carbon. Chromium offers corrosion resistance to stainless steel. Due to this, the die-cast parts are less likely to be affected by rust or corrosion. It can be easily molded into several forms. Thus, manufacturers prefer it for the die-casting process.

Characteristics

  • Extremely durable
  • High tensile strength
  • Corrosion resistant
  • Easy fabrication and formability
  • Low maintenance cost

Alloy Steel

Alloy Steel

Alloy steel is a type of steel that incorporates additional elements, such as chromium, nickel, or molybdenum, to enhance its mechanical properties. These alloys impart improved strength, hardness, and resistance to wear, corrosion, and heat, making alloy steel suitable for various applications in industries like automotive, construction, and aerospace.

Characteristics

  • High strength
  • Improved hardness
  • Enhanced corrosion resistance
  • Heat resistance
  • Versatility for various applications

Carbon Steel

Carbon Steel

Carbon steel is famous for its low cost and versatile nature. Typically, carbon steel is divided into three categories, i.e., low-carbon, medium-carbon, and high-carbon steel. The properties of these types differ according to the carbon content present in the material. Low-carbon steel is known for its good machinability and weldability, whereas high-carbon steel is used in high-strength applications.

Characteristics

  • Very hard
  • Ductile and malleable
  • Relatively low tensile strength
  • Good machinability
  • Low cost

AluminumAluminum

The distinctive characteristics of aluminum make it one of the best materials for die-casting. The major aluminum alloys are A360, A380, A390, A413, ADC12, and ADC1. Among all, the A380 is the most worthwhile aluminum alloy.

Characteristics

  • Excellent corrosion resistance
  • Lightweight
  • High strength and hardness
  • Outstanding thermal conductivity
  • High electrical conductivity
  • Remarkable EMI and RFI shielding properties

 

CopperCopper

Copper is a reddish-orange metal with a face-centered cubic structure that is highly valued for its aesthetics. It exhibits remarkable properties, yet, it can be alloyed with different elements, such as aluminum, tin, zinc, nickel, etc., to improve its characteristics further. The following are some fundamental properties of copper that make it ideal for producing die-casting parts.

Characteristics

  • Very soft
  • An excellent conductor of heat and electricity
  • Good corrosion resistance
  • High ductility
  • Fine malleability

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Ductile Iron

Ductile iron is one type of cast iron that has improved mechanical properties such as strength and toughness due to the presence of nodular graphite in its microstructure. It is known for its ability to be easily machined and high ductility, making it suitable for various applications.

Characteristics

  • High strength and toughness
  • Good ductility and impact resistance
  • Excellent wear resistance
  • Corrosion resistance
  • Good machinability

 

Inconel - https://jiahuicustom.com/

Inconel

Inconel is a family of nickel-based superalloys known for their exceptional strength, heat, and corrosion resistance. They are commonly used in high-temperature environments and applications that require excellent mechanical properties, such as aerospace, gas turbines, nuclear reactors, and chemical processing industries.

Characteristics

  • Exceptional high-temperature strength and creep resistance
  • Excellent resistance to corrosion in various environments
  • Retains mechanical properties at elevated temperatures
  • High resistance to oxidation and scaling at high temperatures
  • Good weldability and fabricability for complex applications.

 

Surface Treatment For Investment Casting Parts

With a comprehensive approach to surface treatment, investment casting parts are transformed into polished, functional, and visually appealing components that meet the demands of diverse industries.

Name
Element
Description
Materials
Color
Texture

Anodizing

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Anodizing improves corrosion resistance, enhancing wear and hardness and protecting the metal surface. This surface finish is widely used in mechanical parts, aircraft, automobile parts, and precision instruments.

Aluminum, Magnesium, Titanium

Clear, Black, Grey, Red, Blue, Gold, White, Silver, Orange, Purple

Smooth, Matte finish

Bead Blasting

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Bead blasting in surface treatment is a process where fine abrasive particles, such as glass beads or ceramic media, are propelled at high speed onto a surface using compressed air. This abrasive action helps to remove rust, paint, or other contaminants, leaving behind a clean and textured surface finish.

Aluminum, Magnesium, Titanium, Copper, Stainless Steel, Steel

Clear

Smooth, Matte finish

Powder Coating

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Powder coating in surface treatment is a dry finishing process where a fine powder is electrostatically applied to a surface. The coated object is then cured under heat, causing the powder particles to melt and form a durable, smooth, and even coating.

Aluminum, Magnesium, Titanium, Copper, Stainless Steel, Steel

Black, Grey, White, Yellow, Red, Blue, Green, Gold, Vertical stripe

Smooth, Matte finish

Electroplating

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Electroplating in surface treatment is when a metal coating is applied to a conductive surface through an electrochemical reaction. It involves immersing the object to be plated in a solution containing metal ions and using an electric current to deposit a metal layer onto the surface.

Aluminum, Magnesium, Titanium, Copper, Stainless Steel, Steel

Clear, White, Black, Grey, Red, Yellow, Blue, Green, Gold, Silver, Bronze

Smooth, Semi-matte, Matte finish

Polishing

Polishing_Investment Casting

Polishing is the process of creating a shiny and smooth surface, either through physical rubbing of the part or by chemical interference. This process produces a surface with significant specular reflection but can reduce diffuse reflection in some materials.

Aluminum, Magnesium, Titanium, Copper, Stainless Steel, Steel

Clear

Smooth, Mirror finish

Brushing

Brushing_Investment Casting

Brushing in surface treatment refers to manually or mechanically applying abrasive brushes to a surface, usually metal, to remove imperfections, create a uniform texture, or enhance its appearance.

Aluminum, Magnesium, Titanium, Zinc, Copper, Stainless Steel, Steel

Clear

Smooth, Matte finish

Electrophoresis

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Electrophoresis is a process in which charged resin particles (ions) in a solution are moved by an electric field and deposited on a metal surface to form a protective coating.

Aluminum, Magnesium, Titanium, Copper, Stainless Steel, Steel

Black, Grey, White, Yellow, Red, Blue, Green, Gold, Silver, Purple

Smooth, Matte finish

Painting

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Painting is especially suitable for the surface of the primary material of metal. It will strengthen the material's moistureproof& rust prevention functions and enhance its compression resistance and internal structural stability.

Aluminum, Magnesium, Titanium, Copper, Stainless Steel, Steel

Black, Grey, White, Yellow, Red, Blue, Green, Gold, Silver, Purple

Smooth, Matte finish

Blackening

Blackening_Investment Casting

Blackening is a standard method of chemical surface treatment that creates a layer of oxide film on the surface of metal to isolate the air and prevent the rust.

Aluminum, Magnesium, Titanium, Copper, Stainless Steel, Steel

Clear

Smooth, Matte finish

Excellent Investment Casting Services

With a focus on precision and ingenuity, we specialize in crafting intricate metal components that redefine accuracy across industries.

Typical Investment Casting Products

Investment Casting - https://jiahuicustom.com/

FAQs Related To Investment Casting

A: When casting thin-walled parts through investment casting, several issues should be paid attention to:

  1. Shrinkage: Thin-walled parts are more prone to shrinkage, leading to distortion or warping. To address this issue, proper gating and riser design should be implemented to allow for sufficient feeding of molten metal during solidification. Additionally, selecting appropriate casting alloys with low shrinkage characteristics can help minimize shrinkage-related problems.
  2. Heat transfer: Thin-walled sections cool down more rapidly, resulting in uneven solidification and potential defects like cold shuts or insufficient filling. It is crucial to ensure proper mold and core temperature control and use insulating materials or coatings to regulate heat transfer during the casting process.
  3. Solidification time: Thin-walled parts tend to solidify quickly due to their reduced mass, making it challenging to achieve complete filling and avoid the formation of voids or porosity. Using optimal pouring techniques, including controlled running rates and implementing vacuum or pressure-assisted casting methods, can help mitigate these issues by ensuring adequate metal flow and reducing the risk of premature solidification.
  4. Mold stability: Thin-walled parts require more delicate handling during mold-making to avoid deformation or damage. Careful consideration should be given to mold materials, design, and support structures to maintain the required dimensional accuracy and prevent distortion.
  5. Surface finish: Thin-walled parts are more susceptible to surface defects such as roughness, pitting, or oxide formation. Proper surface preparation techniques, including mold coating, preheating, and controlled cooling, should ensure a smooth and defect-free surface finish.
  6. Design considerations: When designing thin-walled parts for investment casting, it is essential to consider factors such as draft angles, fillet radii, and wall thickness uniformity. Adequate draft angles allow easy pattern removal, while fillet radii help reduce stress concentrations. Maintaining consistent wall thickness throughout the part minimizes potential casting defects and ensures uniform solidification.
    By paying close attention to these issues, manufacturers can optimize the casting process and achieve high-quality thin-walled parts through investment casting.

A: Bulges in investment casting can occur due to several reasons:

  1. Shrinkage: During the cooling and solidification process, metal contracts and undergoes shrinkage. If the mold has insufficient strength or rigidity to resist this shrinkage, bulges can form as the metal tries to occupy the available space. This can happen when the mold material is not strong enough, or the casting is not properly supported during solidification.
  2. Thermal expansion mismatch: Investment casting involves pouring molten metal into a mold made of ceramic or other refractory materials. A important difference in the coefficient of thermal expansion between the mold material and the metal being cast can lead to bulging as the metal cools and contracts while the mold does not shrink at the same rate.
  3. Inadequate venting: Proper venting is crucial in investment casting to allow for the escape of gases and prevents the formation of trapped air pockets. If the mold is not adequately vented, pressure can build up within the mold cavity, leading to bulges as the metal tries to find ways to escape.
  4. Improper gating and riser design: The design of the gating system and risers plays a significant role in controlling the flow of molten metal during casting. If the gating system is not designed correctly, it can result in uneven metal flow and localized pressure build-up, leading to bulges in certain casting areas.

To prevent bulges in investment casting, it is essential to ensure that the mold has sufficient strength and rigidity to resist the shrinkage forces. Proper selection of mold materials with compatible thermal expansion properties can also help minimize bulging. Adequate venting and well-designed gating and riser systems are essential to control metal flow and prevent pressure build-up.

A: In investment casting, the mold material selection for making core wax depends on various factors such as the casting alloy, complexity of the part, desired surface finish, and the specific requirements of the casting process. The two most commonly used mold materials for core wax are:

  1. Ceramic Shell: Ceramic shell molds are made by repeatedly dipping the wax pattern in a ceramic slurry and then coating it with a refractory material. This process creates a rugged and durable mold that can withstand the high temperatures of the casting process. Ceramic shell molds suit various casting alloys and can provide excellent surface finish and dimensional accuracy.
  2. Silica-based Molds: Silica-based molds, or investment molds, surround the wax pattern with a mixture of silica, binder, and other additives. These molds offer good dimensional accuracy and surface finish. Silica-based molds are commonly used for non-ferrous alloys and are well-suited for intricate or complex parts.

The selection of the mold material should consider factors like the casting temperature, alloy compatibility, mold stability, and the desired quality of the final casting. Consult with us in investment casting to determine the most suitable mold material for your casting requirements.

A: Parting agents are used in investment casting to create a barrier between the mold and the wax pattern or ceramic shell. They help facilitate the easy removal of the pattern or shell from the mold, preventing sticking or damage. Here are some guidelines for using parting agents in investment casting:

  1. Selection of parting agent: Choose a parting agent compatible with the mold material and the casting process. Parting agents commonly include silicone-based sprays, water-based releases, or graphite-based coatings. Consider factors such as ease of use, drying time, and environmental considerations when selecting a parting agent.
  2. Application: Apply the parting agent evenly and thinly on all surfaces that will come into contact with the mold material. This includes the wax pattern, cores, and any tooling or fixtures. Depending on the parting agent's form, use a spray, brush, or dip method. Ensure complete coverage, but avoid excessive application to prevent build-up or contamination.
  3. Drying time: Allow the parting agent to dry thoroughly before proceeding with the casting process. Follow the manufacturer's instructions regarding the recommended drying time. More drying time may result in complete coverage and adequate parting effectiveness.
  4. Reapplication: In some cases, reapplying the parting agent between mold cycles or for multiple wax patterns may be necessary. Follow the recommended reapplication guidelines provided by the parting agent manufacturer.
  5. Cleanliness: Ensure the pattern and mold surfaces are clean and free from dirt, debris, or residual parting agent from previous cycles. This will help maintain consistent parting effectiveness and prevent contamination.
  6. Compatibility: Verify the compatibility of the parting agent with the specific wax or shell material being used. Some parting agents may not be suitable for certain materials, so it is essential to check for compatibility to avoid any adverse effects on the casting process.

A: In investment casting, the lack of material, also known as shrinkage defects or shrinkage porosity, can occur due to various factors during the solidification of the molten metal. Here are some common causes of lack of material in investment casting:

  1. Solidification Shrinkage: When the molten metal cools and solidifies, it undergoes a reduction in volume, resulting in shrinkage. This shrinkage can lead to voids or porosity in the casting if not adequately compensated. Shrinkage defects can occur in the solidifying metal and the cooling ceramic shell.
  2. Insufficient Riser Design: Riser design is crucial in investment casting to provide a reservoir of molten metal that compensates for the shrinkage during solidification. If the risers are too small, improperly placed, or have inadequate volume, they may need to provide more molten metal to compensate for the shrinkage, resulting in a lack of material defects.
  3. Inadequate Gating System: The gating system, including sprues, runners, and gates, controls the flow of molten metal into the mold cavity. If the gating system is designed correctly or has adequate size, it can allow the flow of metal and prevent proper mold filling, resulting in a lack of material defects.
  4. Improper Pouring Techniques: How molten metal is poured into the mold can impact solidification. If the metal is poured too quickly or with excessive turbulence, it can create air entrapment or insufficient filling of the mold cavity, leading to a lack of material defects.
  5. Inadequate Mold or Core Temperature Control: The temperature of the mold and cores can affect the solidification process. If the mold or core temperature is too low, it can cause premature solidification or inadequate mold filling, resulting in a lack of material defects.
  6. Improper Alloy Selection: Some alloys are more prone to shrinkage than others. Choosing an alloy with low shrinkage characteristics can help minimize the risk of lack of material defects.
  7. To mitigate the lack of material defects in investment casting, it is essential to consider proper riser and gating design, controlled pouring techniques, adequate temperature control of the mold and cores, and selecting appropriate alloys. Process optimization and simulation techniques can also predict and address potential shrinkage issues.

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