The Federal Group USA - Investment Casting Process for Impeller Housing

Yi Feng

Jan. 23rd 2014

Manufacturing process for Impeller HousingPart 1: Casting Process

Part 2: Machining Process (to follow)The Federal Group

Copyright 2014 • All Rights Reserved • The Federal Group

21421 Hilltop Street

Southfield, MI 48033

248-545-5000info@tfgusa.comwww.tfgusa.com

1Step 1: Produce wax models

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Step: 1. Set up wax mold, Heat and Inject wax 2. Allow wax to cool3. Remove & Trim Pattern4. Move to storage until

needed

Running Time line: 3 Hours total

Copyright 2014 • All Rights Reserved • The Federal Group

2

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2

Step 1, continued: Produce wax models

1. Each finished parts contains 3 individual pieces .2. It takes 5 minutes to produce each portion.

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2 2

Running Time line: 3.25 Hours totalCopyright 2014 • All Rights Reserved • The Federal Group

3Step 2: Assemble wax model

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1. Clean wax components2. Apply binder to contact surface3-5. Assemble 3 components

6. Final clean up

Running Time line: 4.25 Hours totalCopyright 2014 • All Rights Reserved • The Federal Group

4Step 3: Assemble runner system

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1. Assemble mold gate system2. Assemble whole runner system3. Total time is about 0.5 hour

Running Time line: 4.75 Hours totalCopyright 2014 • All Rights Reserved • The Federal Group

5Step 4: Apply 1st Layer of hard shell

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1. Immerse assembly in slurry2-3. Spray with fine sand 4. Allow to dry for more than 12 hours

Running Time line: 17 Hours totalCopyright 2014 • All Rights Reserved • The Federal Group

6Step 5: Apply 2nd ~10th layer of hard shell

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1. Immerse assembly in slurry2. Spray with fine sand 3-4. Allow to dry for more than 12 hoursApply 8 additional hard shell layers to each part. Total 10 layers when complete.

Running Time line: 126.5 Hours total

Copyright 2014 • All Rights Reserved • The Federal Group

7Step 6: De-wax

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Run 5-6 pcs at a time through the De-way process

Running Time line: 129.5 Hours totalCopyright 2014 • All Rights Reserved • The Federal Group

8Step 7: Casting of product

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Smelt raw material 1. Bake shell2. Pour melting material 3. Solution treatment4. Remove Shell

Running Time line: 133.5 Hours totalCopyright 2014 • All Rights Reserved • The Federal Group

9Step 8: Cut off and clean

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1. Cut runner system with plasma cutting2-4. Ready part to be cleaned with high temperature liquid

Running Time line: 142 Hours totalCopyright 2014 • All Rights Reserved • The Federal Group

10Step 9: Clean and Inspect process

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1. Shot blasting 2. If needed repair with

welding3. If needed clean and grind

welded area4. Inspect part

Final Running Time line: 148 Hours total for each part to complete the casting process.

Copyright 2014 • All Rights Reserved • The Federal Group

248-545-5000info@tfgusa.comwww.tfgusa.com