Harshukh BhattiDirector,Trauma Engineering Services.

Lost Wax/Invest Process History stretches backward beyond the Egypt’s Pyramids/ China / Dwaper Yug of lord Krishna in Artisana and High precision ,Precious and artistic Jewelry & Gold Ornament manufacturing Which remain most popular technique today also . . . .After Dark Ages,Ebullient sculptor & Gold Founder (1766 B C) Benevenuo Cellini claim fascinating autobiography How he make use of “ Lost Wax “which he learned from a description by the Monk Thophilus Presbyter ( circa 1100)Creating Original artistic work on wax model,Coating with milky slurry,forming strong shell by successive coats,melting out wax and pouring a molten gold/silver.

World War II had Ignited development of this process due to sudden huge requirements of Aircraft /Military/ Automobile /ammunition parts mfg which eliminate machining-welding-assembly with high dimensional accuracy ,finish of complex geometry parts.

* Casting Limitation 2.0 Gms to 45 Kilograms per Piece* Casting size 2 Cu mm to 610 Cu mm in size * Minimum Casting Wall thickness 1. 0 To 1.5 mm* Casting Surface finish 1.6/3.2 Micron /80-125 RMS* Delivery Minimum . . . . . . * Dimensional Accuracy>Normal/ +/- 0.2 mm up to 25 mm &+/- 0.1 with each

additional 25 mm thereafter >Premium/Coined +/- 0.15 mm up to 25 mm &+/- 0.08

with each additional 25 mm thereafter* Tolerance VDG-Markblatt P690 class D1 spec

IS -11166-1994* Die Tool Manufacturing Accuracy +/- 50 Micron &

Die Tool Assembly Accuracy +/- 50 MicronPreferable Tooling Manufacturing on CNC.

Harshukh BhattiDirector,Trauma Engineering Services.

8 to 12 week

investment / lost wax casting process

1 Wax pattern Injection

2 Ejection Wax Pattern 1 2 3

3 Cluster Assembly with

casting Methoding.

4 Investing cluster or tree 4 5 6

5 Stucco,Reinforcing Coats

6 Shell Drying

7 De wax the shell mold

8 Firing the shell 7 8 9

9 Metal Pouring

10 Knock out & Fattling

11 Casting finishing 10 11

StereolithographyStereolithography accurate and functional components for the philosophy of “ Test by Design ” base d on the I-DEAS 3D Modelling Software.

A highly accurate components are built up in layers as fine as 0.1 mm helping to ensure highest accuracy,as well as minimizing finishing time by SL 5195 resinspecifically formulated by CIBA Chemicals. The basic resins are Poly Urethane is a technique to produce extremely which have excellent component mechanical strength and good optical clarity, which proved as best prototype pilot model for development.BOING 777 is first world best Craft,100 % Design by 3D solid Modelling on the Globe. The Design Logic was

“Working Together”

3D Solid Modelling for Vane Development

of Suction & Pressure

side of vane

Vane Developmenton 3D Solid ModellingSoftware Master Cam I-DEAS Proengineer. . 3D Solid Modelling

Stereolithography

A defective vane for review

Casting Horoscope. . Megma Software .

Metal contrection

Core support

Hot metal . . bouyancy

Runner/Riser

Volume &

location

Cool rate

Chaplets

ChillsCrack

& Tharmal crack Grain Structure& Micreo

Warpages & Destortion

Porosity Size &

location Cold Shut & Scab

Shrinkages

Location ,

Size

Hot Tears

Blow Holes

Alloying property, sadimentation & furnace charge

Weight,Volume &

Yeild

SoftDietool

Technology

CNC cut Segment DieToolsImpeller Body Tool

Diffuser wax

Die tool

Diffuser CNC WaxDie Tool

At bottom ActualComponent

Segment Die Tool for Pres/Suc vane of Impeller

Water Soluble segment CoreSoluble core disolve inwater flow and form a cavity of an Impeller

IDP & IRDIE TOOLS FOR watersoluble segment core of closeImpeller for Internal cavity at IPCL TOOL ROOM .

All the Die Tools are manufactured on CNC Milling with a acuuracyof +/- 0.001” and assly tole of +/- 0.002 / 0.003“.

Die manufacturing stages:Die Design 3 D Modelling Die Split line Die Construction

Compound Die InsertDie Cooling Wax Pattern

Injection - Ejection DevicesComp’t Volume measurement

Weight Control On “IDEAS & MASTER CAM”software

Open ImpellerDIE ToolCost 1.35 Lac

WAX Pattern with Wax + tool + MetalContraction

9 # Vane Incert Die Tools

425 mm Component Diameter

Soluble segment core are placed in Impeller housing Wax Die for WAX Injection.Soluble wax & WAX pattern are kept in flowing water which dissolve soluble wax & causing cavity in the Impeller wax pattern thus forming vanes of an impeller.

WAX Injection Pressfor Making wax patterns at press. Of 3 to 4 kg/cm2Specially blended Industrial Wax

Mr Carlo Grossi & Mr SubramaniamOn process presentation for Investment & Ceramic Precision casting Production.

Under control temperature18*C & Control rel Humidity.

Ceramic Injection press for making extra high Strength Core to withstand high buoyancy draught, Core lift ,Increase high temp. Core permeability and better Dimensional Control in Ceramic casting. Core segments are pasted to complete circular cavity.

Wax Patterns Ready for Gating system and Methoding

TREE MAKINGIngates & RisersVenting ProvisionsChills/Chaplets provisionsCore supports (by pasting wax rods).Metal Yield 25 % to 35 %

IMPELLER WAX PATTERNUnder Control Temperature

ready with all Methoding requirements byDesign /Method Dept.

WAX Pattern Tree ready for PRIME SHELL COAT

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Prime Shell CoatReinforcing Coats

Silca Bonding --buble Pan -Air strem from Bottam

Prime Shell Coating

•Finish

•Bonding

•Adhesion to pattern

•Refractory Quality

•Zircon base •Flowability & Intricacy.

•Sharpness & clarity.

•Reinforcing of shell.

Secondary Shelling Coats . . . . . .

Quartz silica Colloidal silica Bonding Agents Reinforcing Coats Glass Wool Mat

under control temp.

CORE LIFT CONTROLReinforcing MediaCeramic sec”X I 0 Z ”Hollow Section insidethe cores 8 to 12 CoatMinimum 8/10 Hrs dryExtra strengthening ofshell to prevent bulging & ballooning

IntricacyIn as cast condition 0.15mm Clearence bet’n outer Guide raw and 1st raw lug

Lost wax FeaturesKeyway4 mm hole 1 mm slittingOrientationBore within 0.1OD 110 mmWeight 1.63 kgFinish 95 rmsBalancing accu-racy +/- 5 gms/inch

Ceramic Segments Assembly

Gravity Cast

Centrifugal Cast Core

Injected Casted Core

Reinforcing Core by

I,Z,X,O,H Section inside the core for restricting Bowing / lifting of Core.

Core assembled,locked,pasted and precured

Core repairs,

Core Locking

Core placment

Sealing Cop/Drag assembly

Joint Sealing / pasting / precuring

DEWAXing Chamber / PitsWet Dewaxing InHOT Molten waxpit Dewaxing by Super sature.SteamDry dewaxing by soaking the tree in inverted position and thus cavity formed.Melted Wax is drained away.

Dewaxed Shell hollow from Inside and Ready for Firing /Curing.

Hot metal metallurgical Charge Under preparation. . . . . .

Ferrous Metal charges for required alloying elements+Oxidiser

Control Metallurgy-Spectroanalysis Awaiting Tapping signal from chargman / Metallurgist

FIRING of SHELL

Dewaxed shell at 810*C

Residual wax to burnt Glasswool protection Reinforcing application Soak-time~Shell Volume Fragile Handling of Shell Shell Pouring BED Deoxidiser Masking of Shell

Shell-bed & Pouring810*C fired shell on sand bed Proper seat on bed to absorb metal dropping while Metal Pour Crucible metal to hot fired shell ,Prevent shell puncturing Prevent Oxidation by Flux , Atmospheric Shied by Covering poured shell with help of blind drum with deadweight on top.

Spark Spectro Analyzer

Deoxidizer

Shielding Shell Pouring

Mr Bhatti & Mr Grossi on Shop visit Casting inspection / heat-treatment warp & Torn casting.

COINING Operation for Premium Casting

Restoring Dimension Loss in HT

Restoring Geometry Loss in HT

Restoring Size & Shape loss in Handling

.

Induction HardeningAutomotive Industrial products like Gearbox forks tips at 58/60 Rc

Special holding Fixture for com’t

Specially shaped HF Induction coil for every component.

Induction Furnace Bay

500,250,100, 50 Kilograms

High frequency Induction furnace

Casted components for Heat TreatmentsAnnealing solution annealing Water Quenching Pack Carburizing Case Hardening Normalizing

Shell Breaking hammers & Tree Cutting

Fused ceramic of shell are braked off by pneumatic hammers

Components are separated from cluster/tree by Gas cutter , Sawing ,

Plasma cutter,Diamond Cutters. Hollow Comp’t Internal passages are cleaned by Leaching, Hot NaOH solution for 48 Hrs

Dissolving SilicaHollow Components like ImpellersMr Grossi Verifying Any Fins, Blockage and Obstructions in the Impeller Vane Cavity.Core Lift/Core Breakage, Ballooningrestricting the Hydraulic passages & performance Challenging obstruction & defects.Strictly not AcceptableMetal lumps/fins/obstruction to be removed by Specially designed Curved Tooling & grinder - access remove any irregularities of the passages.Special tooling For Vane Obstruction Removal

Core printCentral corelock

Corelocater

SucDia

Inlet tip Radii 1.5 mm

Perifaral core lock

Pressureside vane

Suctionside Vane

Impeller Cavity

Soluble Core Segment Perameter

Exit tip

Impellers Under Metal Cleaning ProcessShot Blasting Steel / SSSand BlastingAcid CleaningHot NaOH LeachingWire BrushingStretch Filing & fit-ups

Final Designing final Quality Control measures of componentsPre-Tooling Inspection Cad /Cam/tool Insp/Tool assly Insp/wax pattern trialDimensional Inspection confirming Drawing requirements + Geometrical tolePhysical Testing UTS/YP/YS/I Impact test/HardnessMetallurgical Requirements as per customer’s standards/Microscopic exam ’nNon Destructive testing DP,UT,MPT,RT, VI & Compliance of APIHydraulic Testing of Pressure tight ComponentsCommercial Verification Weight Analysis and S Q C Control

Ascertaining Convention Quality Check

Impeller 100% Machining all Over with Six Axis Machining CenterVane Inlet Tip thickness 1.5mm and Bottom Raddi if 1.5mm

Impeller Rotating Speed 20Krpm to 70KrpmRotor assembly-Salvation & Restoration, Rework Dynamic Balancing

And Restoring to design functionality of High Speed turbo machines

With forecasted Capacity or Energy LossAs Interim FIX.

3D ModellingCAD / CAMProgramming3- Axis5-AxisMarching

NDT ComplianceAPI ComplianceOver speed TestBursting Test

5 & 6 Axis Machining of Guide Vane and DiffuserMachining Accurany 25 Micron

Trauma Engineering Services.,

Director

Mr Harshukh Bhatti,

Cell +919376195923 / +919429199089

harshukhbhatti@live.com / harshukhbhatti@yahoo.co.in

A-51, Agrasen Towers, Opp:- BJ Medical College,

Camp Road, Ahmedabad, Gujarat-INDIA-380016