THE LOST WAX PROCESS
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PROCESS STAGE 1: WAX MAKING
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Wax Injection Die
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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. |
Watch the movie about the waxstage
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Injection of wax
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The die is filled
with liquid wax under pressure either by manually operated (for small
quantities) or fully automatic (for large quantities) machines. |
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Ejection of wax pattern
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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. |
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 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. |
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PROCESS STAGE 2: SHELLING
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Dipping in
ceramic slurry
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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. |
Watch the movie about the shellingstage
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Covering with a
ceramic stucco
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Dewaxing
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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. |
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Firing
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After drying the mould is fired in a furnace to achieve its ultimate strength and 'burn' off any remainders of the wax. |
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PROCESS STAGE 3: CASTING
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Melting of the
alloy
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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. |
Watch the movie about the castingstage
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Casting
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The mould is taken out of the furnace and filled with the molten metal. |
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Cooling down
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The filled mould is set aside to cool down. |
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Removing
ceramic shell
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After cooling the mould
is broken away from the metal parts and an initial blasting
operation clears away the majority of the ceramic shell. |
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PROCESS STAGE 4: FINISHING
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Shotblasting
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The castings will now have the last remainder of ceramic removed by shotblasting |
Watch the movie about the finishingstage
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Removing castings
from runner system
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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. |
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 Fettling
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The castings will now have the last piece of the gate removed by grinding. |
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Quality control
and shipment
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After grinding, straightening,
heat treatment and if necessary machining, the casting are ready for
final inspection and ship to our customers. |
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