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Fig. 10.1. Investment casting process description. Once the ceramic has dried, the entire assembly is placed in a steam autoclave to remove most of the wax (Fig. 10.2a). After autoclaving, the remaining amount of wax that soaked into the ceramic shell is burned out in a furnace (Fig. 10.2b). At this point, all of the residual pattern and gating material is removed, and the ceramic mold remains. The mold is then preheated to a specific temperature and filled with molten metal, creating the
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metal casting (Fig. 10.3a). Once the casting has cooled sufficiently, the mold shell is chipped away from the casting. Next, the gates and runners are cut from the casting, and final postprocessing (sandblasting, machining) is done to finish the casting (10.3b). Fig. 10.4 shows the CAD solid model, the shell, and the pattern produced in the QuickCast process.
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Fig. 10.4. CAD solid model (top), ceramic shell with QuickCast pattern (left), QuickCast pattern (right). The major impact rapid prototyping processes have had on investment casting is their ability to make high-quality patterns (Fig. 10.5) without the cost and lead times associated with fabricating injection mold dies. In addition, a pattern can be fabricated directly from a design engineer's computer-aided design (CAD) solid model. Now it is possible to fabricate a complex pattern in a matter of hours and provide a casting in a matter of days. Investment casting is usually required for fabricating complex shapes where other manufacturing processes are too costly and time-consuming. Another advantage of rapid prototyping casting is the low cost of producing castings in small lot sizes.
Fig. 10.5. CAD solid model (top), SLS polycarbonate pattern (left), A356 aluminum casting (right).
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