Meena Cast Pvt. Ltd. following fully equipped self - reliant departments for producing Investment castings.
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1. DESIGN
Following consultation with MCPL, a drawing is supplied to MCPL by the customer, defining the geometry, its required finish and acceptance criteria. Depending upon complexity, tooling is designed with adequate feeding incorporated wherever possible. |
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2. WAX INJECTION
With the help of highly sophisticated design wax injection presses, wax replicas pattern of the preferred castings are produced by injecting wax into a metal Die (Tool) on precise control of the wax temperature and the pressure under which the wax patterns injected are critical. |
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3. WAX ASSEMBLY
Formed wax pattern from single cavity or multi cavity tools are to form a cluster or assembly of tree assembled on wax runners with wax made pouring cup, tie-bar and required handling arrangements for robotic or manual coating. Wax assembly designing is one of the most specific and important stages of the process, which is backed by highly experienced methoding team of engineers.
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4. SHELL BUILDING
The shell is built by dipping the assembly in liquid ceramic slurry and coated with a fine ceramic refractory. Up to eight additional coatings are in this manner to give added strength to the shell applied. The most crucial stage of the shelling process is the primary coating, where a very fine grade of textured sand is used. This in turn results in a casting with excellent reproduction detail and the designated surface finish. After drying, this process is repeated with progressively coarser refractories until a self-supporting shell or mould is formed. |
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5. DEWAXING
Once the ceramic shell is dry; the wax is melted out either by heating under pressure in an autoclave, or heating in wax bath, creating a negative impression of the assembly within the shell. |
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6. CASTING
The hollow shell (after removing the wax) is ready for firing, which pre-heats in shell backing furnace at high temperature to sinter the shell, to remove all residual traces of wax and pre-heat for pouring. Induction melting furnace is used to melt the metal at desired melting point. Strict control of the shell backing temperature & the cooling rate are one of the important factors to ensure metal purity and casting integrity. Having melted and de-gassed the molten metal, the pre-heated shell is filled to the required level and left to solidify. |
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7. KNOCKOUT
When metal filled ceramic shells are fully cooled and solidified, the ceramic shell is broken off from the cast assembly by mechanical vibrating machine vibration or water blasting or chemical cleaning. |
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8. CUT OFF
The cast parts are then removed from the runner system by cut-off wheel or conventional engineering methods. |
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9. FINISHING
After minor finishing operations and appearance achieving by using a variety of blasting techniques and chemical process, the metal castings (identical to the original wax patterns) are ready for shipment to the customer. |
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Facilities to process castings are Cut-off, Sand & Shot Blasting, Belt Grinding (Manual + High Pressure) and TIG welding machines Melt / Heat No. Punching Machine is used to maintain traceability
Heat Treatment Furnace with water quenching facilities adds mettle to the castings. |
