What is Investment Casting?
Investment casting is a complex process where a molten alloy is poured into a ceramic shell to create small, precise metal components. Its original name "lost wax casting," refers to the original wax pattern the ceramics are formed around, then melted and replaced with alloys of stainless steel, aluminum, cobalt, carbon steel, brass, bronze, and other metals.
To begin a discussion on investment casting, the first place to start is its history and etymology. The term "invest" in investment casting stems from the Latin word "investire," meaning "to clothe." In the 1590's, the word "investment" arose from applying "surrounding and besieging" in the context of a military target.
The investment casting process was rooted in ceramics "clothing" or "surrounding" a wax model to produce a metal part.
However, before investment casting, the process was known as "lost wax casting." As early as 5,000 years ago, the lost wax process was used for artistic craftsmanship such as jewelry and sculptures. When the Industrial Revolution began, the need to mass-produce metal and steel parts was at its highest. As a result, the artistic lost wax process turned into the large-scale investment casting process.
The Investment Casting Process
The investment casting process involves creating a wax pattern and layering it with sand and slurry until a strong shell envelopes the model. After melting out the wax, molten steel such as stainless steel or cobalt will be poured into the mold, creating a perfect duplicate of the original wax pattern. Compared to machining a part, investment casting can economically offer undercuts, high definition, complex detail and a smooth surface finish.
Investment casting is most suitable for small parts at large volumes. Most often, investment casting is the only way a part can be economically manufactured with low tooling costs and less material waste. With less waste, it is also better for the environment. If your metal component is small to medium in size and weight, consider investment casting over other processes such as sand casting or die casting.
The investment casting process allows for precision tolerances of 0.005 in/in for parts with complex geometry. For surface finishes, the standard is 120 rms. Our current size capabilities are up to 18 inches and 50 pounds.
If you require prototypes before going into production, we offer rapid prototype services using 3D printing technology and CAD software. These prototypes can be made in just a few days.
Milwaukee Precision Casting, Inc. is a solution for projects of any volume and with over 100 alloys to choose from such as stainless steel, aluminum, and cobalt. We have partnered with some of the most essential industries, such as military, medical, food and beverage, oil & gas, and agriculture, to produce the small parts that keep our society alive.
Get in touch with us today to learn how Milwaukee Precision Casting, Inc. can help.
What Are Lost Wax Investment Castings?
By injecting wax into a permanent-molding die to form wax patterns, investment castings are the solution for many complex parts that are required in large quantities. We produce investment castings in lost wax patterns from a few grams up to 40 pounds, and can economically produce low quantities with manual tooling, or high volumes utilizing multi-cavity automatic molding tools.
The origin of the lost wax investment casting, also known as the lost wax process, stretches back in time to 1100/1700 BC. Works were created from hand sculptured wax patterns with delicate detail. During the post – WWII period, this process evolved and expanded into virtually every industry and marketplace, as seen today.
Frequently Asked Questions
Investment castings are used in almost any industry. From transportation to food processing to solar energy, investment casting is a key manufacturing process for our economy. Investment castings can be used for almost anything where metal components such as steel, aluminum, or brass are required.
Milwaukee Precision Casting, Inc. offers a wide range of finishing work including: machining, heat treating, non-destructive testing, polishing, passivation/electropolishing, deburring/ball burnishing, laser etching, coating, packaging, and more depending on the needs of any part. With have formed close partnerships with many local vendors to ensure that you receive the best casting at the lowest price.
The difference in strength between castings and other methods of metal working, while there, are negligible. Investment castings have been used by the military and medical fields for many years, and are still used in those industries today. Through testing and thorough inspection, we can ensure that no part that leaves Milwaukee Precision Casting would not meet the most rigorous of requirements.
The Investment Casting Process
Click on any of the steps below for detailed information on the investment casting process.
To download the complete casting process guide, please click here.
Investment Casting Material Properties
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