1. PREVAIL CASTING PVT. LTD. WELCOMES DATE: SEPT. 20, 2006

2. OVER VIEW OF INVESTMENT CASTING (LOST-WAX PROCES) DEVELOPMENTS PROCESS

3. Conversion of Paper drg to AutoCAD drg Raster drgVector drg

4. 3-d Model (Sand Casting ) provided by Customer to be converted to investment casting.

5. 3d model converted to suit Investment Casting requirements. Advantage :1. Machining Allowance Reduced. 2. Pilot Holes provided on P.C.D for flanges to reduce machining time.

6. Wax pattern – 3 Patterns made from 3 different tools and assembled for next operation.

7. Design of Die for Aluminum Core and Cavity using I-DEAS software

8. Tool path generation designed by using Unigraphics Software to be transferred to Vertical Machining Center after verification

9. Tool path verification on Unigraphics Software

10. Machining of core die ON 5-AXIS VMC (MAKE : DECKEL MAHO-GERMANY)

11. Inspection of Die with precision measuring instruments.

12. Inspection of Surface finish for the Die

13. Modification of Die : Originally punch was fixed to the side plate causing practical problem while removal of wax pattern from the die. Now its modified by separating punch from the side plate

14. Injection of Wax into the die Opened Die with injected wax pattern.

15. Assembly of wax pattern with gate, runner and riser

16. First Layer of Ceramic Coating Coated wax pattern with approx. 10 to 14 coats

17. De-waxing of ceramic coated shell by dipping into liquid wax De-waxed shell

18. Samples taken during heat for chemical testing on spectrometer along with strip containing heat no. Grinding of Sample for spectro analysis

19. Testing of sample on spectroSpectro result for chemical analysis

20. Tested Scrap Tested Sample

21. Tapping of molten metal in to the ladle Pouring into ceramic shells

22. Knock-out of ceramics from casting

23. Weld Cutting of Gates & Runner of the casting

24. Heat Treatment: Solution Annealing

25. Grinding and Velvet Polishing

26. Microstructure analysis performed on Olympus Microscope equipped with digital camera analysing the structure by using automatic image analyser software to determine % of ferrite & Austenite

27. Physical Tesing by using UTM and Extensometer attached to the Computer. Test Piece

28. Computerized Extensometer giving graph of Stress Vs Strain

29. Removal of Gate and Runners on Lathe Machine Grinding of Gate

30. Fettling & Cleaning of Casting

31. Sand Blasting

32. Dye Penetration Test

33. Visual Inspection of Casting Hydro Testing of casting

34. Testing of Surface Finish

35. Casings in Sand Blasted Condition

36. THANKS….