Process

01
Process

Wax injection

Wax in semi-liquid form is injected in Dies (Pattern/Tools) to produce replica of desired castings. Semi automatic hydraulic press is used to produce wax patterns. All the wax patterns are 100% checked visually and dimensionally.

02
Process

Wax pattern processing

Wax in semi-liquid form is injected in Dies (Pattern/Tools) to produce replica of desired castings. Semi automatic hydraulic press is used to produce wax patterns. All the wax patterns are 100% checked visually and dimensionally.

Wax patterns are assembled to wax runner using wax gates and then wax runner is attached to wax pouring cup to make a cluster or tree.

03
Process

Wax assembly

Wax patterns are assembled to wax runner using wax gates and then wax runner is attached to wax pouring cup to make a cluster or tree

04
Process

Shelling

The wax assembly is coated with a ceramic shell by repeated dipping in ceramic slurries and alternately in dry beds of sand and clays, heavy or thick sections are features of any part, additional coating are to give added strength to the shell.

Thus eliminating bulging or distortion of the casting to complete this stage, the ceramic shell is heated under pressure in an autoclave and the wax removed by melting, leaving a hollow shell.

05
Process

Shelling

The most crucial stage of the shelling process is the primary coating, where a very fine grade of sand is used. This in turn results in a casting with excellent reproduction detail and the designated surface finish.

06
Process

De Waxing

After completing the coating process, the wax is removed by de-waxing process, which is done by putting the ceramic mould in the hot bath of wax

07
Process

Shell Pre Heating

The ceramic shell molds must be fired to burn out the last traces of pattern material and to preheat the mold in preparation for casting, usually in the range of 800 to 1100 degrees centigrade. Amtech use rotary hearth furnesh with three burners which gives very much close control in shell temperature.

08
Process

MELTING

The shell is then subjected to preheating to remove moisture and residual wax, and to sinter the ceramic of shell. The specified alloy, melted in induction furnace, is poured into sintered shells and then shells are left to solidify molten metal.

09
Process

Gate/Riser Cutting

After the metal solidifies and cools, the ceramic shell is then removed by vibratory methods or water blasting.

10
Process

Heat Treatment

Casting to be shot Blasted to remove all small ceramic particles. Amtech also can supply casting with glass bead blasting or sand blasting if customer require.

11
Process

Finishing Operation (Gate Grinding)

Remaining gate protrusions are removed by belt grinding.

12
Process

Final casting inspection

Casting is Heat Treated as per Specifications in 1 ton. capacity heat treatment furnace. Same has been calibrated as per standard APA 6 A.

13
Process

Dispatch

Finally casting is dimensionally and visually inspected, packed as per customer specification and dispatched. Before Despatch All testing to be done like Die Penetrate Test, Magnetic Particle Test, Radiography Test etc. based on customer specification.