Investment Casting Process

CLUSTER
CERAMIC MOLD
INVESTMENT CASTING
COMPONENT

The most important phase for long life, high quality and high performance products is the moulds and tooling with accurate design. Moulds made of duraluminium or steel can be manufactured with one or more multiple cavities depending on production quantities.

High quality technical wax with constant shringake ratio is used. Wax patterns are pressed in semi automated vertical or horizontal presses. If it is needed, wax cores are also produced at this stage.

Wax patterns are assembled to wax runners and sufficient number of wax runners to casting sprues.

Molten metal is poured in ceramic shells. Wax trees are dipped in special formulated ceramik slurry. Ceramic sand is applied on ceramic sludge using sprinkling or fluidized bed technology. Colloidal silica as a binder and zirconium oxide / aluminium silicate as a refractory material are used inside the ceramic slurry. During ceramic moulding, humidity and temperature of the environment should be under control to minimise casting defects

Wax inside the ceramic is melted and removed in an aoutoclave under pressure and heat to form the casting cavity. This process is done under 7 bar and 200oC for 15-20 minutes.

Ceramic mould is sintered to increase its strength and to be ready for the casting

Required alloy, mainly iron. steel, copper and aluminium, is melted in induction or aluminium furnace. Smelting and casting in ceramic shells are performed with care not to have a negative affect on microstructure.

After solidification of the molten metal seramic shell is broke and removed.

Depending on customer requirements, different processes (heat treatment, machining, coating) are applied to the end product.

Final inspections such as dimensional checks, mechanical testing, and non-destructive testing are conducted to verify the compliance of the produced parts with the specifications.

Variety of Cast Alloys

Egeli Precision Casting is capable of casting hundreds of alloys in both the Iron-Steel Group and the Non-Ferrous Group.
In the Iron-Steel Group, Egeli Precision Casting is capable of casting non-alloy, low-alloy, and high-alloy steels, as well as Nickel and Cobalt-based alloys.

In the Non-Ferrous Group, Egeli Precision Casting is capable of casting all suitable Aluminum and Copper alloys for casting.
Due to our expertise in materials science, we collaborate with our customers in selecting the most suitable material for service conditions and provide all our knowledge and experience as an integral part of creating added value.

While there is an endless number of alloys that can be cast in our foundry, the most commonly requested alloys are listed below:

Alloys We Can Pour:

Austenitic Stainless Steel
Tool Steel
Cobalt Base Alloys
Low Alloy and Carbon Steels

Nickel Base Alloys
Copper Alloys (Brass / Bronze)
Martensitic Stainless Steel
Aluminium Alloys

From Idea to Product

We collaborate with our customers to realize designs related to materials, geometry, and production processes, starting from the idea or rough design stage all the way to a finished, usable product.

We take full responsibility for the production of all molds and tooling, utilizing our experienced mold makers who are capable of accurately replicating the shrinkage rates of materials such as wax, ceramics, and cast metals in different geometric sections, all in a single mold.

We take responsibility for the production of designs that require other manufacturing methods, in addition to our core competencies in investment casting and machining, through our subsidiaries or partner organizations. These production methods are employed when necessary to meet specific design requirements, ensuring a comprehensive and integrated manufacturing solution for our customers.

Forging
Extrusion
Injection molding
Coating

Heat treatment
Surface treatments
MIM

These are just a few examples of other manufacturing processes that we can mention.

In general, among our services that can be summarized as material/product characterization, we can mention dimensional inspection, chemical analysis, microstructure analysis, mechanical testing, and non-destructive testing methods.