The injection moulds are produced thorough machining processes of high precision (via CAM - computer aided manufacturing). Its composite is perfectly moulded and designed according to the part's engeneering process.
The first process in the manufacturing of investment cast parts is the high temperature liquid wax injection in the cooled matrices. This process is carried out in high precision injection equipment under careful control of pressure and temperature.
The Wax Tree
Each of the parts in rigid wax is now joined with and linked to a wax sprue forming a tree liked structure with the units put together, this structure will receive the slurry baths in the next steps.
Each of the wax trees will be covered with different ceramic slurry baths, especially developed, forming once hardened, a ceramic covering with the required structure and resistance.
In this particular step the wax tree with its ceramic cover shall be put into an autoclave where the wax removal from the mould will take place through steaming, creating therefore, a ceramic mould. The wax that runs out of the mould will be directed to a recovering system for later reuse.
The ceramic moulds are taken to a furnace at a temperature of about 1000 degrees Celsius, removing any wax left and providing the mould with the required resistance and stiffness.
The elaboration of the metal alloy follows strict specifications required by customers whose chemical composition is verified and assured during the investment casting process through a spectrometer.
Casting CGP (counter gravity pouring process)
It's in this particular step that Fupresa's main quality differential is applied. The ceramic mould adequately heated is placed into a metal chamber putting the mould in contact with the liquid metal which will be aspired by vacuum (CGP - counter gravity pouring process) fulfilling the mould cavities forming the final parts.
Once thoroughly cooled, the shell shall be submitted to controlled impacts, blasted,vibrated, breaking the ceramic shell in order to release the solid metal parts and remove the ceramic residues.
The finishing is done part by part, either by computer numeric control (cnc) machines or by other more more specific equipment or processes.
After all the processes are finalized the parts are submitted one by one to a “poka-yoke” device where well trained professionals inspect the final product which will later be wrapped according customers specifications.
An Investment casting guide
Fupresa has prepared a complete guide aimed at engeneering professionals. This guide provide them with technical information, definitions and concepts of very high value about the investment casting process and it's advantages and applications.
Investment casted parts as a substitute for:
forged and fondry
The greater the impact of machining cost over the final cost of forged or fondry products, the greater the advantage in the adoption of the CGP (counter gravity pouring process) manufacturing process.
As the CGP (counter gravity pouring process) process allows for extremely thin walls (from 1mm) it become viable the development of items with substantial weight reduction when compared to other possible processes of fondry or forging.
The freedom for designing products with complex shapes is another competitive advantage the CGP (counter gravity pouring process), because the conventional processes present several restrictions to the adoption of more complex geometrical shapes.
Welded and machined
Products obtained through welding of different metal components can be supplied with economical advantages when adopting the CGP (counter gravity pouring process) process if the welded product to be replaced by the investment casted product requires operations which may result in an increase in the final cost, such as machining or straightening.
Machining processes of steel bars with low machinability have been replaced with great success by the CGP (counter gravity pouring process) process.
Built of investment cast parts associated to components obtained by other technologies such as plastic, rubber,nuts and bolts.
Such as straightening, coinage, machining,frequently used in order to meet the needs of the dimensional or geometrical specifications, which cannot be obtained directly in the investment cast part.
Technologies of metallurgical finishing, such as heat treatment under controlled atmosphere and induction hardening, are internally available.
Electroplating treatment are also available through subcontract with qualified and ISO-9000 certified suppliers.
Better yield of molten metal
Substantial energy saving process
Higher number of parts per mold
PARTS WITH GREATER RESISTANCE AND DURABILITY
TOTAL FREEDOM IN THE PROJECT OF THE PART
Substancially lower cost
Much better quality
AddressRod. Engº Ermenio de O. Penteado - CEP: 13.347-600
KM 47,6 Indaiatuba/SP
TelephonesMain: 55 19 3885 9600
Sales: 55 19 3885 9605
Sales: 55 19 3885 9608
Office HoursMon. to Thu. - 7:30 às 17:15hr Fri. - 7:30 às 16:40hr