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Manufacturing
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Product design and manufacturing of wax injection dies Upon receiving an order for a part, we shall maintain a close contact with customer's design engineers to ensure what exactly the customer requires. Dimensional tolerance and material option will be discussed in detail. Final drawing for casting will be resolved and agreed upon. The design of the tooling required for investment casting or foam-casting will be completed by our expert design engineers within the time frame specified by the project manager. Puladir Investment Casting Co. has a complete set of machineries for manufacturing wax injection dies and tooling for foam-injection dies. Knowledgeable staff and technicians will manufacture dies according to design provided. After completion of dies, the wax pattern and steel samples of the part will be produced and submitted to customer for approval. Any modification required by client will be applied at this stage until the approval of customer is obtained before mass production.
2. Investment Casting process Investment casting commonly referred to as "lost wax process" starts with injecting molten wax into the dies to form a pattern. This is done by using an automatic or semi-automatic wax injection machine depending upon the number of parts ordered. Patterns are glued to wax runner bars to form an assembly referred to as a "tree". In the next step the process of dipping the trees into slurry followed by sanding the trees through rain machine or fluidized bed. This process will be repeated in several stages until a ceramic "shell" is built up. After drying, the Wax removal of the ceramic shell molds will be done by steam autoclaves. After the wax removal, The molds are heated to high temperature in order to burn out any residual wax. Metal is poured into the fired shell and left to be cooled. The ceramic shell will be shaken out by knock-out machine and the metal pieces are cut-off by grinding machines. The precision castings are subjected to further heat treatments and shot blast.
3. Foam Casting Process Foam-Casting also referred to as "Lost-Foam Process" resembles the Investment Casting Process except for the patterns which are produced by injecting the foam into special dies designed for this process. The dies will be supported by loose sand for stability. The fact that lost-foam process need less coats in building up a ceramic shell mold, and using of foam instead of wax, makes the lost foam castings less expensive with respect to investment casting.
4. Machining Puladir Investment Casting Company has a machining shop equipped with complete sets of machineries and equipments needed for precision machining of parts. Lathes, milling, drills, CNC machines and much other equipment are provided in a separate workshop about 2000 m² .
5. General Inspection, Quality Control Although the quality control is applied to all stages of investment casting or foam casting process, a final general inspection will be applied to all shipments of parts before delivery. For each shipment, a complete test report is provided that includes material analysis, dimensional measurements, mechanical test results and any other information required by the customer. |
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