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Induction Casting Technologies

Home/LEARN ABOUT INDUCTION HEATING/Induction Casting Technologies
Induction Casting Technologies 2016-10-18T08:17:40+00:00

SUPERCAST, EASYCAST*, CS DIGITAL*

Air purging image image
To secure optimal environment for clean and successful casting, the melting chamber is consecutively deep vacuumed (1) and refilled with argon (2). This process is cycled several times to make sure all oxygen is entirely evacuated. The last stage is backfilling the chamber with argon to prepare it for melting and casting.

Melting image

Heating is turned on as soon as the chamber is backfilled with argon. An optical sensor is continuously monitoring the alloy temperature as a built-in temperature controller is following the best temperature profile.
The alloy is also visible through a view-finder for better process control.

Injection and Compression image
When the molten alloy reaches casting temperature, an injection and compression cycle is started by following a precise spin profile. It makes sure that the right centrifugal force and right force duration is applied for successful casting. A patented technology utilizes non-interrupted heating process to avoid premature alloy solidification.

Centrifugal casting technology

PRESSCAST

Material Loading image
Ingots or scrap are loaded prior to process initiation.

Air purging image image 
To secure optimal environment for clean and successful casting, both melting and casting chambers are consecutively deep vacuumed (2) and refilled with argon (3). This process is cycled several times to make sure all oxygen is entirely evacuated. The last stage is backfilling the chambers with argon to prepare them for melting and casting.

Melting image
Heating is turned on as soon as both chambers are backfilled with argon and the flask is raised up to position. An optical sensor is continuously monitoring the alloy temperature as a built-in temperature controller is following the best temperature profile. The alloy is also visible through a view-finder for better process control.

Injection and Compression image
When the molten alloy reaches casting temperature, an injection and compression cycle is started by raising the plunger and applying the right pressure and vacuum. Pressure is applied to the melting chamber, while vacuum is pulled from the casting chamber. That eliminates miscasting and significantly reduces shrinkage porosity. For the best results, a precise vacuum/ pressure profile is followed for the whole duration of the injection and compression phase.

pressure casting technology

ULTRACAST

Ultracast is a patented proprietary technology that combines the crucible and flask in one to reduce cost and increase efficiency.

pressure casting technology

Flask preparation

  • Tree wax model is built on a reusable rubber base (supplied).
  • Ceramic tube is placed around the tree wax model and is filled with investment material.
  • Flask is pulled from the rubber base once the investment material solidifies.
    • Flask is placed in a burnout furnace for investment material curing.
      Wax melts down, leaks out and opens model cavity.

      • Once burnout is completed, the flask acquires crucible functionality as well.
        While hot, the flask/crucible is filled with ingots or scrap.

pressure casting casting technology

UltraCast loading image
Ingot-filled hot flask/crucible is placed on the platform inside UltraCast machine. (1)

Chamber sealing image  
The platform is raised up to position and a mini chamber is closed and sealed. (2)

Air purging  image
To secure optimal environment for clean and successful casting, the mini chamber is consecutively vacuumed (2) and refilled with argon (3). This process is cycled several times to make sure all oxygen is entirely vacuated. The last stage is backfilling the chamber with argon to prepare it for melting and casting.

Melting image
Heating is turned on as soon as the chamber is backfilled with argon. An optical sensor is continuously monitoring the alloy temperature as a built-in temperature controller is following the best temperature profile. The alloy is also visible through a view-finder for better process control.

Injection and Compression image
When the molten alloy reaches casting temperature, an injection and compression cycle is started by applying the right pressure to the chamber. Pressure is precisely monitored and regulated so it is strong enough to push molten alloy through the channels at the bottom of the crucible. For the best results, pressure duration is precisely controlled as well.