BRIEF HISTORY

Investment Casting using the lost wax technique is not new on the country, it is one of the oldest casting methods known and examples of its use to produce statuary and jewelry can be traced back to antiquity. In the early part of this century the method was applied to the manufacture of gold fillings and dental inlays for false teeth, while in 1932, the lost was ceramic block mould process was developed using cobalt-chromium alloys for dental applications and orthopedic components. The demands of the Second World War changed the limited application of the technique and the wake of the introduction of the aircraft gas turbine and intensified development of turbo chargers for highflying bombers and fighters, designers were drawn to Investment Casting to produce the necessary high quality components.

The 1950's saw the expansion of the industry, mainly allied to aircraft and military applications but with a significantly increasing involvement in the general commercial field. With the introduction, in the mid of 50's of the ceramic shell mould process, the range of materials cast increased dramatically and to the original alloys, copper alloys, magnesium alloys, and more recently, titanium alloys, typifying the versatility of the process.

WHY CHOOSE INVESTMENT CASTING?

Investment Casting produces near-net-shape configurations, offering designers and engineers freedom to design the part of maximum function. The process is capable of producing precise details like complex undercuts, slots, holes, lettering and dimensional accuracy in parts weighing many kgs. or just few grams. The Investment Casting Process has distinct advantages over other manufacturing methods. These advantages include:

FLEXIBILITY OF DESIGN : Investment Castings can be manufactured with complex features, such as 3D counters, thin walls and undercuts.

CLOSE TOLERANCES AND CONSISTENCY : Control of process variables results in closer tolerances and excellent product consistency.

HIGH STATIC AND DYNAMIC MECHANICAL PROPERTIES : Controlled solidification casting techniques yield components with improved mechanical properties.

ECONOMICAL FOR PROTOTYPE AND PRODUCTION QUANTITIES : Prototypes as well as large production runs can be produced economically. Moreover, by incorporating many functional features in to a single casting, the break-even quantity can be lowered significantly.

FREEDOM OF ALLOY SELECTION : Components can be manufactured with the aluminum, titanium or super alloy best suited to the application.

GOOD SURFACE FINISH : Components can be cast with ultra-smooth surfaces without resorting to expensive secondary operations.

LOWER TOTAL COMPONENT COST : A complex casting with many functional features reduce the number of sub-assemblies and the overall manufacturing cost.

ELIMINATION OF MACHINING : Well-engineered designs that select the most effective and functional dimensioning and tolerance techniques minimize the need for subsequent machining operations.

WIDE CHOICE OF ALLOYS : Even Alloys that cannot be cast by other methods or which are difficult to machine can be Cast, more than 100 ferrous & non ferrous metals are routinely cast.

INVESTMENT CASTING PROCESS is the solution of following four key problems:

» Casting had to be reproducible within close dimensional limits

» Casting had to be produced in high melting point alloys

» There had to be standards of metallurgical quality