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BMM 3643
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Investment Casting
Also called the lost-wax process
The pattern is made of wax or a plastic
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process.
BMM 3643
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(4) (5) (6) The pattern is then dipped into a slurry of refractory
material such as very fine silica and binders, including water, ethyl
silicate, and acids.
After initial coating has dried, the pattern is coated repeatedly
to increase its thickness until the mould is completed.
BMM 3643
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(7) The mould is dried and heated to a temperature 90 175C. It is held for
about 12 hours to melt out the wax. Then it is fired to 650 1050C for about
4 hours to drive off the water and burn off any residual wax.
(8) Then the molten metal is poured and solidified.
(9) (10) The mould is broken up and casting to be removed
BMM 3643
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Expandable-Pattern Casting
Process (cont.)
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Expandable-Pattern Casting
Process (cont.)
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Expandable-Pattern Casting
Process (cont.)
5. The molten metal is poured into the mould. This immediately vaporizes
the pattern and fills the mould cavity. The heat degrades (depolymerizes)
polystyrene and the products are vented into surrounding sand.
6. Once cooled, the parts are shakeout to get the final products.
BMM 3643
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(a)
(b)
(a) Metal is poured into mold for lost-foam casting of a 60-hp. 3-cylinder marine
engine; (b) finished engine block. Source: Courtesy of Mercury Marine.
BMM 3643
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Lost-foam Casting
(Evaporative-pattern casting)
Advantages:
No parting lines, cores, risers etc.
Inexpensive flasks are satisfactory.
Polystyrenes are in expensive
Net shape process (no secondary work)
BMM 3643
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