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Airfoils, LLC

SMP Plant

 Investment Casting Process - Overview
Also known as the LOST WAX PROCESS.  Wax is injection molded in a die to form a dimensionally accurate pattern of the desired geometry with the added features or gating required to manufacture the casting.  Individual patterns are assembled onto a wax cluster.  The cluster is dipped into a ceramic slurry, coated with ceramic sand, and dried.  This process is repeated several times until a mold shell of the necessary thickness has formed around the wax.  The wax is removed from the ceramic mold in a steam autoclave or gas fired furnace.  Metal is then poured into the mold in a specially designed furnace to control the way the metal solidifies.  Solidification control yields Equiax, Directionally Solidified, and Single Crystal castings with enhanced properties for high temperature, high stress, applications like turbine airfoils.  The shell is removed from the cast mold and the individual castings are cut off of the mold.  Most castings are heat treated to further enhance casting properties.  The gating is removed with a variety of techniques and machinery including:  belt grinders, wheel grinders, CNC saws, and CNC mills.  Castings are finished with a variety of belts and stones to remove any remaining gating evidence and ensure visual quality.  Castings are dimensionally verified using an assortment of dedicated gages, CMM, and ultrasonic wall  inspection.  Before shipment, further NDT Inspection includes:  Internal Airflow, Fluorescent Penetrant Inspection (FPI), and X-ray.

 

Investment Casting Process - Photo Tour

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Wax Injection Click to open in new window Wax Pattern Click to open in new window Wax Assembly
Click to open in new window Ceramic Dip Click to open in new window Ceramic Dip Click to open in new window Steam Autoclave
Click to open in new window Mold Fire Click to open in new window Cast Click to open in new window Knockout & Cutoff
Click to open in new window Grain Inspection Click to open in new window Gating Removal - Belt Grinder Click to open in new window Finishing - Belt
Click to open in new window Finishing Stone Click to open in new window Gaging Click to open in new window CMM
Click to open in new window Ultrasonic Wall Click to open in new window Airflow Click to open in new window FPI
Click to open in new window X-ray        
Export Control:
Diversion of these products/technologies and/or software from the authorized destination contrary to U.S. and international law is prohibited. The Purchaser agrees to comply with applicable laws and regulations of the United States, other relevant jurisdictions, and pertinent international organizations pertaining to the export, deemed export, re-export, or release of these products/technologies and/or software. Any violations of this clause, as determined solely by any PCC Airfoils, LLC facility shall be deemed a material breach of this Agreement.