Raw Materials Pre-treatment
- Pattern material: The pattern is generally made with wax. Precision - machined pattern copies with high precision the shape of machinery component. The pattern should have a minimal amount of contraction as well as high fluidity on injection in order to have dimensional accuracy in pattern.
Pattern making
- Injection moulding: The melt state is achieved by heating the wax. The melted wax is forced into a mould made of metal. The mould is designed according to design specification requirements of machinery component. The shot with high pressure fills the entire mould cavity with a highly accurate pattern in the form of wax.
- Pattern Assembly: A cluster pattern can be cast on a cluster of runners. The cluster is cast in a manner that more than a single component is cast in a single operation with improved production efficiency.
Shell Building
- Dipping and Coating: The cluster of wax pattern is initially dipped in a slurry consisting of silica sol and a refractory power material, i.e., zircon sand or alumina. The cluster is subsequently coated with a layer of a coarser form of refractory sand in order to add on the shell. The operation is repeated a couple of times, generally 4 - 6 layers, in order to attain the appropriate shell thickness as well as strength.
- Drying: The pattern cluster is allowed to dry between each coating and dipping in a conditioned room. The drying time as well as drying temperature are both kept with great care not to crack as well as dry uneven.
Dewaxing
- Steam Autoclaving: The patterned shell is deposited into a steam autocclave. The high-pressure steam is made use of in order to melt out the wax, which leaves from the shell in small channels or holes. A cavity is thus achieved in the shell with a shape that is a perfect fit with that of the machinery component.
Casting
- Melting Metal: The appropriate alloyed metal that is supposed to be used in machinery component, i.e., steel with carbon, aluminum alloy, or stainless steel, is melted in a furnace. The procedure is observed with keen interest in a bid to attain the perfect chemical compound as well as perfect molten metal temperature.
- Pouring: The metal is cast in pre - heated shells in a controlled process. Gravity pour or assist - pour in a vacuum can be made in order to fill in a complete as well as a perfect shape.
Post - processing
- Shell stripping: The shell is removed from the solidified metal by means of mechanics, i.e., shot blast or vibration.
- Finishing Operations: The cast component can be subjected to a variety of finishing operations, which involve machining, grinding, as well as heat treatment. The final dimensions as well as surface finish are obtained through machining, whereas heat treatment can enhance the component's mechanical properties.
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