Investment Casting
Investment casting is one of the oldest manufacturing processes, dating back thousands of years,
in which molten metal is poured into an expendable ceramic mold. The mold is formed by using a
wax pattern - a disposable piece in the shape of the desired part. The pattern is surrounded, or
"invested", into ceramic slurry that hardens into the mold. Investment casting is often referred to
as "lost-wax casting" because the wax pattern is melted out of the mold after it has been formed.
Lox-wax processes are one-to-one (one pattern creates one part), which increases production
time and costs relative to other casting processes. However, since the mold is destroyed during
the process, parts with complex geometries and intricate details can be created.
Investment casting can make use of most metals, most commonly using aluminum alloys, bronze
alloys, magnesium alloys, cast iron, stainless steel, and tool steel. This process is beneficial for
casting metals with high melting temperatures that can not be molded in plaster or metal. Parts
that are typically made by investment casting include those with complex geometry such as
turbine blades or firearm components. High temperature applications are also common, which
includes parts for the automotive, aircraft, and military industries.
Investment casting requires the use of a metal die, wax, ceramic slurry, furnace, molten metal,
and any machines needed for sandblasting, cutting, or grinding. The process steps include the
following:
1. Pattern creation - The wax patterns are typically injection molded into a metal die and are
formed as one piece. Cores may be used to form any internal features on the pattern.
Several of these patterns are attached to a central wax gating system (sprue, runners, and
risers), to form a tree-like assembly. The gating system forms the channels through which the
molten metal will flow to the mold cavity.
2. Mold creation - This "pattern tree" is dipped into a slurry of fine ceramic particles, coated
with more coarse particles, and then dried to form a ceramic shell around the patterns and
gating system. This process is repeated until the shell is thick enough to withstand the molten
metal it will encounter. The shell is then placed into an oven and the wax is melted out
leaving a hollow ceramic shell that acts as a one-piece mold, hence the name "lost wax"
casting.
3. Pouring - The mold is preheated in a furnace to approximately 1000°C (1832°F) and the
molten metal is poured from a ladle into the gating system of the mold, filling the mold cavity.
Pouring is typically achieved manually under the force of gravity, but other methods such as
vacuum or pressure are sometimes used.
4. Cooling - After the mold has been filled, the molten metal is allowed to cool and solidify
into the shape of the final casting. Cooling time depends on the thickness of the part,
thickness of the mold, and the material used.
5. Casting removal - After the molten metal has cooled, the mold can be broken and the
casting removed. The ceramic mold is typically broken using water jets, but several other
methods exist. Once removed, the parts are separated from the gating system by either
sawing or cold breaking (using liquid nitrogen).
6. Finishing - Often times, finishing operations such as grinding or sandblasting are used to
smooth the part at the gates. Heat treatment is also sometimes used to harden the final part.
Investment Casting
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Capabilities
Typical Feasible
Shapes: Thin-walled: Complex Flat
Solid: Cylindrical Thin-walled: Cylindrical
Solid: Cubic Thin-walled: Cubic
Solid: Complex
Part size: Weight: 0.02 oz - 500 lb
Materials: Metals Cast Iron
Alloy Steel Lead
Carbon Steel Magnesium
Stainless Steel Tin
Aluminum Titanium
Copper Zinc
Nickel
Surface finish - Ra: 50 - 125 μin 16 - 300 μin
Tolerance: ± 0.005 in. ± 0.002 in.
Max wall thickness: 0.06 - 0.80 in. 0.025 - 5.0 in.
Quantity: 10 - 1000 1 - 1000000
Lead time: Weeks Days
Advantages: Can form complex shapes and fine details
Typical Feasible
Many material options
High strength parts
Very good surface finish and accuracy
Little need for secondary machining
Disadvantages: Time-consuming process
High labor cost
High tooling cost
Long lead time possible
Applications: Turbine blades, armament parts, pipe fittings,
lock parts, handtools, jewelry
