Liquid wax is added to a molding die to get the desired shape of the final product for creating a wax pattern.
WAX PATTERN ASSEMBLY
The wax patterns are attached to a pouring cup, struts, gate, and runner as per the shape and size of the pattern.
COATING
Ceramic coatings are applied in the wax pattern assembly. The main stage of the coating process is the primary coating, where a fine grade of sand is used to have castings with an exceptional surface finish.
DEWAXING
Wax pattern assembly with multiple coatings transformed into a shell after de-waxing. Wax inside the solid ceramic coating is eliminated in liquid form by applying pressurized steam. Cycle time is a key parameter to be controlled during de-waxing.
MELTING
The shells are pre-heated to eradicate residual wax and moisture content from the shell and to sinter the ceramic of the shell. The specified grade melted in the induction furnace is then transferred into pre-heated shells and shells are left for solidification.
KNOCKOUT & CUTTING
The ceramic shell is separated with the help of a vibrating knockout machine and each casting is cut away by gas cut-off or arc welding method.
HEAT TREATMENT
We have batch type furnace with fast quenching facility, which is used to improve mechanical properties, and to get proper microstructure results. The furnace is adjusted to API 6D and there is systemized control for a real-time temperature of diverse zones.
FETTLING
We perform fettling to eliminate excess in gates and complete the product with final surface finish and abrasive grinding with electro polishing, greet shot blasting, or as per customer requirements.
FINAL INSPECTION
Inspection is considered a vital part of the engineering process. We, therefore, inspect each batch with respective drawings, required gauges and instruments to cover customer requirements.
FINAL PACKING
Final products are packed in a wooden box or according to our customers. We apply anti-corrosion oil castings of carbon steel to avoid rust.