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Precisiewerk Zierikzee BV

THE LOST WAX PROCESS

PROCESS STAGE 1: WAX MAKING

Wax Injection Die
The starting point of our process is a wax injection die (tool). These tools are designed by us to suit the part and manufactured by toolmakers.

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Watch the movie about the waxstage


Injection of wax
The die is filled with liquid wax under pressure either by manually operated (for small quantities) or fully automatic (for large quantities) machines.

 


Ejection of wax pattern
By means of an ejection system, incorporated in the tooling, the wax is 'lifted' from the die. This wax is an identical copy of the part to be cast.  
Mould assembly
A batch of identical waxes is mounted on a runner/feeding system, complete with preformed ceramic pouring cup, in preparation for the ceramic shell application.

 

PROCESS STAGE 2: SHELLING
Dipping in
ceramic slurry
The now assembled mould is washed and rinsed in order to remove mould release agents and dirt. Following a drying time this mould is dipped in a ceramic slurry to evently coat the waxes and runner system. After draining the mould is 'covered' with a ceramic stucco to strengthen the coating. This process is repeated 6 to 8 times to achieve a ceramic shell, with drying periods in between each coat applied.

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Watch the movie about the shellingstage

Covering with a
ceramic stucco
Dewaxing
After final drying the moulds are placed in an autoclave and the wax is removed by means of superheated steam. The wax returned from the autoclave will be recycled for repeated use.

 

Firing
After drying the mould is fired in a furnace to achieve its ultimate strength and 'burn' off any remainders of the wax.

 

PROCESS STAGE 3: CASTING
Melting of the
alloy
The required alloy is melted and brought to its required pouring temperature. In the meantime the mould has been heated to a certain temperature to lessen the 'thermal' shock upon pouring of the molten metal.

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Watch the movie about the castingstage

Casting
The mould is taken out of the furnace and filled with the molten metal.  
Cooling down
The filled mould is set aside to cool down.  
Removing
ceramic shell
After cooling the mould is broken away from the metal parts and an initial blasting operation clears away the majority of the ceramic shell.  
PROCESS STAGE 4: FINISHING
Shotblasting
The castings will now have the last remainder of ceramic removed by shotblasting

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Watch the movie about the finishingstage

Removing castings
from runner system
The castings are now removed from the runner system. The remaining runner system is now sorted according to metal type and after analysis, prepared for remelting or discarded as scrap and returned to a metal recycling firm.  
Fettling
The castings will now have the last piece of the gate removed by grinding.  

Quality control
and shipment
After grinding, straightening, heat treatment and if necessary machining, the casting are ready for final inspection and ship to our customers.