Production Process
- Pattern making: A pattern is cast in wax initially. The pattern is a replication in perfect shape of resulting pump component. 3D advanced modeling as well as CNC machining can be made use of in order to attain high precision. The pattern clusters are developed by placing clusters of pattern in wax on a sprue.
- Shell Building: The cluster of pattern is treated with a sol silicon sol followed by a fire-resistant material layer. The process is repeated multiple times in order to create a thick layer of a ceramic shell over a pattern. The bonding is very good with a sol silicon, giving a dimensionally stable high-strength shell.
- Dewaxing: The patterned wax in the ceramic shell is melted in a furnace or in an autocclave. The melted wax drains out, which leaves a cavity in the shape of a pump component in the ceramic shell.
- Casting: Pre - heated ceramic shell is charged with cast steel, cast iron, or bronze molten metal. The pump component is assumed by shape from the metal. Either cast steel, cast iron, or bronze can be made material on pump requirement basis. Either structural requirement for strength can be either requirement.
- Shell Breaking Off and Finishing: The metal is hardened once cast. The cast pump component is then treated with a range of surface finishes, machining, as well as heat treatment in a move towards attaining the desired surface condition, dimensions, as well as mechanics.
Advantages for Pumps
- Complex Geometry: Silica sol casting can be utilized in order to cast pump elements having complex external as well as internal geometry, i.e., having curved-blade impellers. The pump is made more efficient with enhanced fluid flow.
- High Dimensional Precision: The achievement of high dimensional tolerancing with ideal fit between pump components. Leakage is minimised, as is overall pump operation as well as pump reliability.
- Surface quality: The process attains a surface quality that is as ideal in removing friction as in wearing out, specifically in fluid-handling devices with abrasived fluid.
Applications
Silica sol cast pump parts are applied in a vast array of industries from power production to water treatment, from petroleum as well as gas industries to chemical processing. Silica sol cast pump parts are used in centrifugal pump, diaphragm pump, as well as gear pump.
Quality Control
- Inspection at Every Stage: In production, quality is thoroughly inspected at every stage. For example, dimensional precision is inspected in case of models that are cast in wax, as is with shells that are cast in ceramic.
- Non - destructive Testing: After casting, non - destructive testing, i.e., ultrasonics as also X - ray examination are conducted in order to determine internal defects in pump parts.
- Mechanical Testing: The casted parts are also undergone with mechanical testing, i.e., hardness as well as tensile strength, in a prescribed manner.
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