Step 1

The investment casting process begins with a tool that is built to create a wax pattern of the casting ultimately desired by the customer. This tool is built to specifications directed by the customer and can create a wax that will ultimately hold precise dimensional requirements to ten thousandths of an inch per inch.

Step 2

The first production step is to create the wax patterns using the tooling specified by the customer. The tool is placed against a cold wax injection machine. Wax is forced into the cavity of the tool, and once removed is used to create the eventual casting. PPCP uses a proprietary wax system that produces excellent dimensional stability.

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Step 3

The next step is assembling the wax patterns onto a sprue. The gating and sprue ultimately feeds the molten metal as the casting is being formed during the pouring process. PPCP's technical staff designs a set up that will yield superb cast results while minimizing excess use of valuable raw materials. Operators affix the wax patterns to the sprue following directions contained in the QA Display system.

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Step 4

During the dipping process, successive layers of liquid ceramic and stucco are applied until a robust ceramic shell is created. The first primary coats consist of zircon materials. PPCP uses a blend of Fused Silica and Alumina Silicate materials for the backup coats. Shells must be dried between the coats. Shells typically consist of 6 to 12 coats of material. PPCP uses robotic and manual dipping to ensure the process is perfectly matched for the configuration of the casting.

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Step 5

The mold is next placed into a flash fire de-wax oven which burns out the wax and sprue materials. Only the hollow mold remains. Raw steel components are melted and a sample is drawn and analyzed on a spectrometer, and any final adjustments are made. The molds are pre-heated to 1800 degrees f and then placed into a sand bed. The molten steel (up to 3000 degrees f) is transferred into the mold. Once the metal is solid, it is ready for further processing.

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Step 6

The ceramic shell is next broken away from the metal sprue and castings. Then the individual castings are cut from the sprue and gates. The gates remaining on the casting are ground to customer specifications. Heat Treating is next used to make the castings harder, softer, or more corrosion resistant. Castings are then blasted with shot to remove any scaling or residual ceramic. The castings are inspected thoroughly to determine they meet or exceed the needs of the end user.

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Step 7

Many customers specify additional testing to be completed prior to the shipment of a casting. PPCP completes a full range of non-destructive testing including Magnetic Particle Examination (MAG), Liquid Penetrant Testing (LP), Radiographic Testing (X-Ray, RT), and more. PPCP can save customers time and money by machining areas so that the component is ready to use out of the box.

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Step 8

Lastly, our Quality Assurance department reviews all information about the castings prior to shipment. The process flow is monitored to ensure no steps were missed or incomplete. All testing reports are reviewed in great detail to ensure each requirement on the purchase order has been accomplished satisfactorily. Once these details have been completed, the order is then released for shipment to the customer.

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