Production Procedure
- Pattern making: A pattern in plastic or in wax is developed as a copy in conformity with pump design requirements. The pattern is a duplicate of the resulting pump component. There is a high possibility with high-tech CAD/CAM in producing high-precision patterns.
- Mold Assembly: A cluster is developed with over a single shape that is supported on a central wax sprue. The cluster is infiltrated in a water - glass slurry with a surface layer made up of a layer of refractory sand. The process is repeated two times in order to form a tough, thick mold shell.
- Dewaxing: The mold case is melted with heat in order to melt out the pattern made out of wax. A cavity shaped like the pump component is thus left in the mold.
- Melting and pouring: The cast steel, cast iron, or material chosen is melted in a furnace. The metal is cast into pre - heated mould shells in a state that is in a state once it is brought into its appropriate mix and heat.
- Cooling and shakeout: The metal in mould is allowed to cool and solidify after pouring. The mould shell is later broken away (shakeout) to leave the approximate pump component.
- Finishing Operations: The cast pump part undergoes various finishing operations, including machining, grinding, and surface treatment, to meet the final dimensional and surface quality requirements.
Advantages in water - casting in pump manufacturing.
- Cost - effective: In relation to some technologies in precision casting, water - glass casting is relatively cost - effective, especially in mass - production on small - to - large scale.
- Good Dimensional Integrity: Dimensionally, it is comparatively high in terms of its integrity in order that pumps will be in sound condition. The castings are comparatively tightly tolerated, which keeps excessive machining at a minimal level.
- Suitable with Complicated Geometry: The water - glass casting is also appropriate in casting pump parts with complicated geometry, i.e., with tricky blade geometry in case of an impeller which is not as simple with traditional machining.
Quality Control
- Material Testing: The raw material, both mould material as well as metal alloy, is in a manner that is in conformity with quality requirements. The material is analysed on a basis of chemicals as its physical attributes are also evaluated.
- Dimensional Inspection: The pump component is measured both before as well as after casting with highly accurate instruments, i.e., coordinate measuring machines (CMM), in order to be quantified in terms of design specification.
- Non - Destructive Testing: Ultrasonics, X - Ray examination, magnetic particle examination are also used in detecting internal defects, i. e., pores as also crack in cast pump parts.
Applications from Supplied by water - glass Casting
- Industrial Applications: They are also made use in power generation, mining, as also in chemicals industries. They can pump corrosive chemicals, hot water, as also slurries.
- Domestic Use: Domestic application makes water - castings available in water supply networks, heating networks, as also in sewage treatment.
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