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Lost-Wax Casting - How Does It Work?

The lost-wax casting process is utilized worldwide, and the method is typically chosen by engineers. It offers flexibility when it pertains to product design and the products used. There are applications for which you intend to utilize the lost-wax casting process and instances when it's not the best casting option.

What Is Lost-Wax Casting?

Lost-wax Casting (or investment Casting) is a multi-step process that is used to create duplicate items from a solitary mold. The mold is developed from the original item ensuring that all others are precise reproductions. Engineers can make use of a range of metals that include gold, silver, bronze, brass, and steel. The item designs vary from basic to complex.

The "lost wax" technique is so-called because of the wax model. The strategy is in some cases called the "lost mold” method because the mold, too, is ruined in the process.

How long has the Lost-Wax Casting technique been around?

The procedure referred to as lost wax casting is not a new technique. Archeologists have discovered instances of the procedure going back hundreds of years in Mesopotamia, Africa, and South Asia. Currently, the earliest instance of financial investment casting is an amulet attributed to the Indus Valley Civilisation that was carbon-dated to about 3,700 B.C.E or close to 6,000 years ago.

Because the old times, artisans from around the world have actually made metal precious jewelry pieces, sculptures, and various other things with the lost wax spreading strategy.

 

Benefits of Lost-Wax Casting

Using investment casting, as opposed to various other item manufacturing approaches comes with several advantages.

- Parts are precise and specific copies of the original.

- The casting process also makes certain uniformity and reduces costs for both time and labor.

- You'll get precision parts at a reduced cost.

- Casting surface coating is much above that of other casting methods

- Mold is heated up prior to putting allowing for thinner measurements of areas.

When to Use Lost-Wax Casting

Make use of the lost-wax Casting process when the same part is needed for a high-volume order. If the parts need accurate measurements or have an intricate design, investment Casting is the suggested method to utilize.

The lost-wax casting process is also optimal when an order calls for the very same component in a range of sizes or materials. Complicated layouts and smooth coatings are also assisted by the investment casting approach.

Hope you find the article useful. Thanks for reading it.

What is Iron Casting Manufacturing Process of Cast Iron Castings

Iron casting is the process of liquefying pig iron in a furnace and pouring the molten iron into a mold until it hardens. The iron thus obtained is used in various industrial applications. The cast iron is brittle, has a great strength-to-weight ratio, weak in tension, and a good compression strength. The composition of cast iron and the method of manufacture play a major role in determining the characteristics of this alloy.

Pig iron is the type of iron used for casting iron. The casting method is used to make parts and products that cannot be obtained by other manufacturing processes due to their unique design and size. Traditional casting methods comprise lost wax casting, plaster mold casting, and sand casting. The modern casting process is subdivided into two main categories: expendable and non-expendable casting. Expendable casting uses temporary, non-reusable molds. However, in the case of non-expendable casting, molds need not be changed every time.

Basic process involved

Over 70% of all iron castings is produced using sand casting. Cast iron manufactured through this process is produced in foundries.

1.Obtaining casting geometry and pattern making

Firstly, the required design is prepared by the engineers in consultation with the customers using CAD or other computer-aided designs. Based on the blueprint, the pattern is prepared. The pattern is a physical model of the casting used to make the mold. It is built using sand, metal, or plastic. When the pattern is withdrawn, the imprint provides the mold cavity.

This cavity is used to fill the molten iron casting. If the casting needs to be hollow, as in the case of certain parts like pipe fittings, extra patterns, such as cores, are used to form these cavities. It is important to remember the pattern must be slightly larger than the finished product, a difference known as contraction allowance.

 

2.Coremaking

Cores are patterns that are made of sand and placed into a mold cavity to form the interior surface of the casting. Hence, the casting obtained is the void space between the core and mold cavity surface. The cores are generally inserted into the casting box after removal of the pattern. Whenever possible, designs avoid the use of cores as they add up to the set-up time and hence incur a greater cost.

3.Molding

The next step in the process involves preparing the mold for receiving the molten iron. The mold along with the core with a supporting frame is placed around the pattern. The pattern is withdrawn leaving the mold cavity and core. Once the pattern is removed, the mold is closed.

4.Melting and pouring

The pig iron is liquefied in a capola furnace between 1,150 to 1,200 °C (2,100 to 2,190 °F), which is about 300 °C (572 °F) lower than the melting point of pure iron. When the iron melts at the desired temperature, it is transferred and poured into designed molds. The molten iron is left to harden.

5.Cleaning

When the cast iron solidifies, sand, scale, and excess metal are removed. The casting is separated from the mold and transported to the cleaning section. Burned-on sand and scale are removed to improve the surface appearance of the casting. Excess metal in the form of fins, wires, gates, etc. is also removed. Casting may undergo further processing like heat treatment as well as inspection and machining may be performed on cast iron.

When the process is complete and impurities are removed, the end product is not 100 percent iron. The chemical makeup like carbon and silicon make up the composition of cast iron in various percentages. Anything over two percent of silicon is known as gray cast iron, while a lesser amount produces white cast iron.

Find out more information here - OTTOMMO CASTING

OTTOMMO Casting has been dedicated to delivering high-quality Iron Casting, Grey Iron Casting, Ductile Iron Casting. Our Iron Casting foundry offers you sand casting and investment casting options.

Iron Casting Foundry | Ductile Iron and Grey Iron Casting | OTTOMMO

 OTTOMMO Casting has been dedicated to deliver high-quality iron parts. Our Ductile Iron Casting foundry offers you sand casting and investment casting options.