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Manufacturing Process
Investment Casting Process:
Customer Drawing:
From using 2D drawing of investment casting provided by customer, we check errors or modification using CAD/CAM. We send drawing to customer for approval making appropriate changes in drawing based on lost wax casting process requirement. We technically support our customers for developing cost effective product based on material/machining cost savings.
Dye Making (Tools Making):
From using Approved drawing of investment casting provided by customer, we manufacture die (pattern/tools) of Aluminum material using CAD/CAM.
Wax Injection- Wax in semi-liquid form is injected in Dies (Pattern/Tools) to produce replica of desired castings. Semi automatic hydraulic press is used to produce wax patterns. All the wax patterns are 100% checked visually and dimensionally.
WAX PATTERN PROCESSING- Wax in semi-liquid form is injected in Dies (Pattern/Tools) to produce replica of desired castings. Semi automatic hydraulic press is used to produce wax patterns. All the wax patterns are 100% checked visually and dimensionally. Wax patterns are assembled to wax runner using wax gates and then wax runner is attached to wax pouring cup to make a cluster or tree.
WAX ASSEMBLY- Wax patterns are assembled to wax runner using wax gates and then wax runner is attached to wax pouring cup to make a cluster or tree
SHELL CERAMIC COATING- The wax assembly is coated with a ceramic shell by repeated dipping in ceramic slurries and alternately in dry beds of sand and clays, heavy or thick sections are features of any part, additional coating are to give added strength to the shell. Thus eliminating bulging or distortion of the casting to complete this stage, the ceramic shell is heated under pressure in an autoclave and the wax removed by melting, leaving a hollow shell.
DE-WAXING- The wax inside the ceramic mold is melted out utilizing steam in an industrial autoclave and the wax is recycled.
SHELL BAKING- After wax is removed, a ceramic mold is then heated to 1800 degrees Fahrenheit in a preheat oven. The heating of the mold fuses the ceramic particles so the mold can withstand the pressure and temperature of the upcoming molten metal. It also removes all traces of organic materials. The preheating of the shell improves the ability to cast fine detail and improves the feed of liquid metal to compensate for volumetric shrinkage.
METAL POURING- Molten metal is poured into the preheated molds. Standard pouring temperatures are approximately 3,000 degrees Fahrenheit for steel. With every melt pour, the heat's chemicals are analyzed spectrographically to assure compliance with customer specifications. The process of investment casting allows customers to choose from a wide variety of alloys since any alloy can be investment cast economically.
CLEANING & CASTING REMOVAL- After the metal-filled mold is cooled, the ceramic shell is removed with high-pressure jets of water.
After the shell is removed and the metal parts are exposed, the components need to be removed from the metal sprue. MARUTI INV Steel Cast uses our proprietary processes to safely remove the components.
CUTTING AND POLISHING- Since some components require more applications than investment casting alone can supply, Maruti Inv Steel Cast offers a full range of finishing services.
Final Inspection & Dispatch- The final castings are inspected dimensionally. The okayed castings are sent to dispatch department. Here, prior to packing, if necessary the castings are stained with oil avoid rusting over the surface.
Customer Drawing:
From using 2D drawing of investment casting provided by customer, we check errors or modification using CAD/CAM. We send drawing to customer for approval making appropriate changes in drawing based on lost wax casting process requirement. We technically support our customers for developing cost effective product based on material/machining cost savings.
Dye Making (Tools Making):
From using Approved drawing of investment casting provided by customer, we manufacture die (pattern/tools) of Aluminum material using CAD/CAM.
Wax Injection- Wax in semi-liquid form is injected in Dies (Pattern/Tools) to produce replica of desired castings. Semi automatic hydraulic press is used to produce wax patterns. All the wax patterns are 100% checked visually and dimensionally.
WAX PATTERN PROCESSING- Wax in semi-liquid form is injected in Dies (Pattern/Tools) to produce replica of desired castings. Semi automatic hydraulic press is used to produce wax patterns. All the wax patterns are 100% checked visually and dimensionally. Wax patterns are assembled to wax runner using wax gates and then wax runner is attached to wax pouring cup to make a cluster or tree.
WAX ASSEMBLY- Wax patterns are assembled to wax runner using wax gates and then wax runner is attached to wax pouring cup to make a cluster or tree
SHELL CERAMIC COATING- The wax assembly is coated with a ceramic shell by repeated dipping in ceramic slurries and alternately in dry beds of sand and clays, heavy or thick sections are features of any part, additional coating are to give added strength to the shell. Thus eliminating bulging or distortion of the casting to complete this stage, the ceramic shell is heated under pressure in an autoclave and the wax removed by melting, leaving a hollow shell.
DE-WAXING- The wax inside the ceramic mold is melted out utilizing steam in an industrial autoclave and the wax is recycled.
SHELL BAKING- After wax is removed, a ceramic mold is then heated to 1800 degrees Fahrenheit in a preheat oven. The heating of the mold fuses the ceramic particles so the mold can withstand the pressure and temperature of the upcoming molten metal. It also removes all traces of organic materials. The preheating of the shell improves the ability to cast fine detail and improves the feed of liquid metal to compensate for volumetric shrinkage.
METAL POURING- Molten metal is poured into the preheated molds. Standard pouring temperatures are approximately 3,000 degrees Fahrenheit for steel. With every melt pour, the heat's chemicals are analyzed spectrographically to assure compliance with customer specifications. The process of investment casting allows customers to choose from a wide variety of alloys since any alloy can be investment cast economically.
CLEANING & CASTING REMOVAL- After the metal-filled mold is cooled, the ceramic shell is removed with high-pressure jets of water.
After the shell is removed and the metal parts are exposed, the components need to be removed from the metal sprue. MARUTI INV Steel Cast uses our proprietary processes to safely remove the components.
CUTTING AND POLISHING- Since some components require more applications than investment casting alone can supply, Maruti Inv Steel Cast offers a full range of finishing services.
Final Inspection & Dispatch- The final castings are inspected dimensionally. The okayed castings are sent to dispatch department. Here, prior to packing, if necessary the castings are stained with oil avoid rusting over the surface.
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