Yi Feng Jan. 23 rd 2014 Manufacturing process for Impeller Housing Part 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 248-545-5000 [email protected]www.tfgusa.com
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The Federal Group USA - Investment Casting Process for Impeller Housing
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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
Running Time line: 4.25 Hours totalCopyright 2014 • All Rights Reserved • The Federal Group
4Step 3: Assemble runner system
1 2 3
4
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
1 2
3
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