Meena Cast Pvt. Ltd. is well equipped with ultra-modern machinery and technologies to follow department-wise investment casting. Facilities in process casting consist of cut-off, manual and high-pressure belt grinding, sand and shot blasting, as well as TIG welding machines. Heat treatment furnaces and water quenching services add metals to these investment castings. Here is our process:
1. Design
After getting a consultation from Meena Cast Pvt. Ltd., a drawing is provided to us by the client, defining geometry, required finishing, and reception criteria. As per the complexity, tooling can be designed with suitable feeding included wherever possible.
2. Wax Injection
Molded wax patterns from the single or multi-cavity tools create an assembly or cluster of the tree-assembled proceeding wax runners, which have wax-made pouring cups, tie-bars, and necessary handling arrangements to provide manual or robotic coating. The designing of wax assemblies is among the most precise and significant stages of the procedure, backed by our highly experienced engineering team.
3. Wax Assembly
Molded wax patterns from the single or multi-cavity tools create an assembly or cluster of the tree-assembled proceeding wax runners, which have wax-made pouring cups, tie-bars, and necessary handling arrangements to provide manual or robotic coating. The designing of wax assemblies is among the most precise and significant stages of the procedure, backed by our highly experienced engineering team.
4. Shell Building
The shell can be built by dropping the assembly into the melted ceramic slurry, as well as by coating it with good ceramic refractory. Eight additional coatings are given to provide additional strength to the applied shell. The most important stage of this shelling procedure is its primary coating, in which textured sand of superb quality is used. This actually results in an investment casting with outstanding reproduction details and chosen surface finishing. After drying, the process is again repeated with coarser refractories until the self-supporting mold or shell is made.
5. Dewaxing
When the ceramic shell becomes dry, its wax is melted either through heating under pressure with an autoclave or heating in the wax bath, making a negative impact on the assembly in the shell.
6. Casting
After the removal of the wax, the hollow shell is all set for firing, and the pre-heats in the shell help the furnace at a higher temperature to trash the shell, removing all the residual traces of wax as well as the pre-heat to pour. Induction melting furnace can be used for melting metals with an anticipated melting point. Severe control over shell backing temperature as well as cooling rates are among the significant factors in ensuring investment casting integrity and metal purity. Having melted as well as degassed the melted metal, a pre-heated shell reaches the necessary level with the required solidify.
7. Knockout
When the metal-filled ceramic shells are solidified and fully cooled, the ceramic shells are broken from the cast assembly through mechanical vibrating machines, vibrations, chemical cleaning or water blasting.
8. Cut Off
Then, the cast parts are removed from a runner system through cut-off wheels or predictable engineering techniques.
9. Finishing
After a negligible finishing appearance achieved using different blasting methods and chemical procedures, the metal casting (same as the original wax pattern) is all set for shipment to our customer.
10. Verification
Each & every stage of the process is followed by Traceability and Routine Inspection according to the Activity Charts.
