investment casting

Metall.

a casting process in which an expendable pattern is surrounded by an investment compound and then baked so that the investment is hardened to form a mold and the pattern material may be melted and run off. Also called precision casting. Cf. lost-wax process.

[1945-50]

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Precision casting for forming metal shapes with minutely precise details.

Casting bronze or precious metals typically involves several steps, including forming a mold around the sculptured form; detaching the mold (in two or more sections); coating its inside with wax; forming a second mold, of heat-resisting clay, around the wax shell, and filling the interior with a clay core; baking the assembly (hardening the clay and melting the wax, which escapes through openings in the outer mold); pouring molten bronze into the space vacated by the wax; and breaking the mold to expose the cast form. In modern foundries, plastics, or occasionally frozen mercury, are used instead of wax. See also lost-wax casting, die casting.

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      precision-casting technique for forming metal shapes. A typical process for bronze castings involves six steps:

      1. A gelatin mold is formed around the solid sculptured form.

      2. The mold is removed (in two or more sections) from the sculptured form, and the inside of the mold is filled with wax or coated with a layer of wax of the same thickness as that desired for the final casting.

      3. The outer gelatin mold is then removed, and a second mold, of heat-resisting clay, is formed around the wax shell, the interior of which is filled with a clay core.

      4. The mass is baked, hardening the clay and melting the wax, which runs off through openings in the outer mold.

      5. The hardened mold is packed in sand, and molten bronze is poured through the openings to fill the space vacated by the lost wax.

      6. The mold is broken, and the bronze form remains.

      In modern foundries, plastics (plastic), or occasionally frozen mercury, are used in place of the wax. Coated with a refractory cement instead of clay, the mold is packed in a porous cement, dried, and heated. The plastic melts, leaving cavities to be filled with molten metal. For all except the smallest forms, the molds are usually made in sections. The process is used for manufacturing jewelry, dentures, sculpture, and many small industrial parts that require minutely precise details. See also lost-wax process.

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