Lost Wax Casting: Everything You Need to Know

The process of casting lost wax, which is also referred to as investment casting, or precision casting has been the most well-known and popular casting technique for a long period of time. It’s been the process that is preferred by many particularly because of its precision as well as its ability to reproduce specifics consistency, repeatability, and integrity.

The Story of Casting Wax in the Lost Age

Casting with wax has been in use over thousands of years and the first documented examples of this method believed to be from 3700 BC after testing using carbon-14 dating. They were discovered within the Cave of the Treasure hoard in southern Israel. Another early example that show the casting procedure can be found in a myriad of regions and countries as well.

In the ancient region of Mesopotamia Lost wax casting was extensively employed for both large and small-scale casting. In South Asia, Pakistan, an amulet made of copper that was 6,000 years old created using this technique was discovered. Egypt, Greece East Asia, Africa, Europe… objects created using this method have been found across the globe.

The process of casting lost wax is utilized to create intricate, detailed metal components which are later used in a variety of applications and industries. This method may have started many thousands of years ago and yet it is a key element in the casting process of today.
How does Lost Wax Casting work?

Lost wax investment casting is a relatively standard procedure. That means that while every foundry has its own method of casting a particular metal however, the process is generally identical for all. It involves a number of steps, beginning with the making of a wax model , and finishing with the final metal piece.

The steps of this procedure usually consist of:

Making an aluminum tool out of the 3D CAD data
Making a positive model of a part made of wax using the tooling
The wax is put together using a runner system (‘tree’)
The shell of a ceramic is constructed around the assembled part by an dipping and drying process (investment)
The shell is then dewaxed by high-pressure steam, then baked in an oven to give the required durability
Molten metal is put into the pre-heated shell
The ceramic is broken after the metal cools.
The pieces are cut off the “tree”
The Ingate (feed position) is ground
If needed setting, finishing, and machining can be completed
Specific NDT inspection requirements and specifications

What and when is the Lost Wax casting Process used?

There are numerous ways to use lost wax casting across a variety of industries. For quite a long time the technique was used to create jewelry and small components and also to create sculptures. But, today, investment casting is a part of the majority of industries’ supply chains, which includes the medical sector (knee or hip implant) as well as rail, automotive and mining industries, aerospace industry and nearly any other manufacturing method that requires precise metal components.

Which metals are used to make Wax Casting?

This process is flexible that means a broad range of materials are used to make high-quality products regardless of whether they’re lightweight or sturdy uncommon or common. The types of products we use to make our castings include:

Stainless Steels as well as Heat Resistant Castings of Lost Wax

The stainless steel material is a versatile choice for castings and is utilized in a variety of industries. It is constructed from an amalgamation of chromium, molybdenum, and nickel. The grain and the properties of the alloy made using stainless steel are determined by the concentrations of each of the metals. Since chromium is always 10 percent of the alloy the alloys are immune to oxidation and corrosion.

Carbon steel Castings with Lost Wax

Most often, it is chosen because of its low price, cost-effective and ferromagnetic characteristics, carbon steel can be found in various grades, and is able to be flexible in its ductility using heat treatment. The carbon steel alloys typically employed in the agricultural, aerospace, medical , and firearm industries.

Alloys of nickel and cobalt

As with stainless steel the nickel and cobalt alloys are not oxidized, however , both offer solid resistance to wear, heat and corrosion. This is why you frequently discover these alloys are suitable for industries that have extreme temperatures and corrosion are possible for example, military, marine, chemical and aerospace. They can be paired with aluminum and iron to produce Alnico an alloy that provides a permanent magnet that is used in turbine blades, magnetron tubes as well as jet engine engines.

Alloys based on copper

Copper-based alloys are extremely electrical and thermal conductivity, as well as low wear and tear, and excellent ductility. They are commonly found in the plumbing, marine, as well as electrical sectors. Alloys that contain copper are bronze that is used in boat propellers and bearings as well as brass used in instruments for music pipes, explosives and plumbing and cooper-nickel that is often used to create castings in maritime industry.

Aluminium Lost Wax Castings

Castings made of aluminum lost wax are well-known due to its durability and machinability. Due to its fluidity, alloys of aluminium can have thin walls. When combined with other metals, or heated, the metal is able to build up a remarkable strength. It is among the most abundant because it comprises 8percent of the earth’s crust. It is a very light metal that is used in the military, aerospace packaging, automotive food preparation, and electrical industries.

What are the benefits of Lost Wax Casting?

The lost wax casting method is used for small, intricate components, since it gives an exceptional level of design and precisionYou can include numbers, product identification logos, product IDs, and much more to the casting that is made with this method. The investment casting process is also one technique that does not typically require much additional processes, like polishing because the finish on the surface is superior to other types of casting. It also produces finished parts that have tighter tolerances than other methods like sand casting making it possible for post-machining, and its associated costs can be drastically decreased or eliminated completely.

This method offers a variety of advantages as well, both in terms of design and cost. In contrast to other methods the draft angles aren’t required , and parts can be made lighter by reducing the amount of machine work. Our investment casting of the highest quality is able to provide many other benefits, including as much as 30kg of capacity for casting (and as much as 150kg of China casting capacities) and shorter UK lead times and small to large runs as well as Baseefa and Atex certified parts. At DGI we provide 3D design assistance with thermal treatment, digital simulations of casting and a variety of finishing options.

Casting with lost wax is a very technological process that requires knowledge and experience throughout the process, so that the finished products are of the highest integrity and quality. A high level of process control is crucial to keep high standards for quality. We take pride in our extensive knowledge of investment casting. do not hesitate to inquire about our services . A team member will talk about your requirements with you.