Material Selection
- Base Metal: The suitable metals suitable for application in gas as also in oil are alloy steel, stainless steel, as also carbon steel, which are selected on component requirements, i.e., heat resistance, strength, as also resistance towards corrosion.
Pattern making
- Pattern making: The gas as well as the oil parts are made in 3D with great precision with the assistance of CAD software. The highly shaped details in the final product are duplicated with great precision.
- Pattern Materials: Polystyrene is generally utilized. The wax is also utilized because it leaves a good surface finish as well as is simple in terms of release from cast. The pattern is either developed through injection molding or machining in order to be very dimensionally accurate.
Molding Process
- Coating application: The design from polystyrene or from wax is soaked in a water-glass paste that is a combination between water with a refractory material - The coating is deposited in a sequence with particles with a variety in each - The coats at beginning have particles that are smaller in a move towards attaining a surface finish that is not as rough, with coarser particles in succeeding coats.
- Drying: The patterns are dried in a controlled condition following each coating application in order to dry out moisture and allow the coating to harden. This is important in establishing a firm and level mold shell.
- Pattern Ejection: The pattern is forced out from drying as also from becoming hardened. In a pattern cast in wax, it is obtained by heating the mould shell in a device having a source of steam or in a high-pressure autoclave that melts out the wax.
Melting and casting
- Metal Melting: The raw metal is melted in a furnace at suitable heat. Carbon steel, for example, is melted at 1500 - 1600°C. There is rigorous heat maintenance in a manner that the metal is in suitable fluidity as well as having suitable ratios of chemicals.
- Pouring: The metal is cast in a pre - heated mould shell in a directed manner. Gravity pouring or methods of low - pressure pouring can be made as a function of component complexity as well as component size.
Post - casting Treatment
- Shell stripping: The metal is solidified before stripping its mould shell by means which are mechanical in nature, i.e., vibration or sandblasting.
- Heat Treatment: The heat - treated castings in order to enhance their mechanical properties, i. e., toughness, hardness, and strength. Some common heat - treatments are annealing, quenching, and tempering.
- Machining And Finishing: Final dimensions as also surface finishes are machined in castings as in case of application of gas as also application of oil. The work can be turning, as also can be milling. The non - destructive ultrasonic examination as also magnetic particle examination are also carried out in order to inspect whether internal flaws are present.
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