By utilizing almost any type of alloy, the metal investment casting process produces parts and components with a near limitless variety of shapes. Metal investment casting also provides a way to incorporate virtually an unlimited number of features directly into the mold. Aero Metals has been casting metal parts through the investment casting process for nearly 60 years. Our world class 175,000 square foot facility features the industry’s most technologically advanced equipment. We are able to produce in high volumes to service your project needs.
With more than 120 different ferrous and non-ferrous casting alloys available, Aero Metals can produce metal castings using a wide range of metal alloys for unlimited metal investment casting applications. The metal investment casting process is very versatile and produces a wide range of metal cast assemblies for a range of industries. Investment cast metal parts provide the maximum design flexibility for manufacturing complex, one-part components.
Contact us for more information regarding our metal investment casting options, or call us at 219-326-1976 and we will gladly answer any questions. Aero Metals is your trusted resource for high quality and high volume investment casting metal parts.
Metal Investment Casting Mold Construction
An investment casting mold (or shell) is formed by first producing a disposable wax pattern resembling the metal part being produced. The pattern(s) is attached to a wax tree which is then dipped, or "invested", into ceramic slurry and then covered in fine sand and dried. This dip-sand-dry process is repeated to create a lamination that hardens into the mold (or shell) to withstand the molten metal to be poured into it. The shell is then placed into an oven and the wax is melted out leaving a hollow ceramic mold ready to be cured in high temperature industrial ovens.
Metal Investment Casting Advantages
Due to its extreme versatility, accuracy and total manufacturing value, investment casting is a highly productive way of producing a wide range of metal parts and components. The advantages precision investment castings can provide your company includes:
- High dimensional accuracy
- Excellent surface finish
- Mold and part versatility
- Can cast nearly any metal
- No flash or parting lines
- Can cast extremely intricate parts
Metal Investment Casting Beneficial Processes
When producing repeating quantities of highly complex, intricate parts or assemblies, no other fabrication technique can equal the cost-performance superiority of metal investment casting. At Aero Metals, we provide the following process advantages, delivering casting metal parts that are produced to your project’s exact specifications:
Lower Tooling Costs
Aero Metals produces its molds in-house and maintains them free of charge for the life of the program. We utilize the latest solidification software technology and innovative practices to ensure consistent and precise wax patterns when manufacturing your cast metal parts.
Reliability is engineered into every metal cast part. The metal investment cast process at Aero Metals is tracked through a state-of-the-art ERP system, monitoring our production to ensure quality and reliable metal casting through put and process controls. We also adhere to our certified ISO quality procedures to deliver repeatability from lot to lot.
Tight Tolerance Control
Aero Metals is capable of holding +/- 0.005.” However, under certain conditions tolerances of +/- 0.003” can be achieved. Tighter tolerances beyond typical investment cast standards are achieved by post-cast processes such as straightening (hot or cold), coining, broaching, and machining.
Metal investment casting is produced from wax patterns, which are reclaimed, cleaned, and reused time and time again. Metal investment casting also produces parts to net- or near-net shape, which significantly reduces, or eliminates, secondary machining waste. Metal casting is a very green and eco-friendly process.
Unlike many other casting production methods, metal investment castings do not require any draft. The design engineer is free to incorporate such features as under-cuts, logos, numbers, and letters into the metal casting component. In addition, through holes, slots, blind holes, external and internal splines, gears, and thread profiles can be cast to reduce secondary machining time and total part cost.