Casting Process Control
Investment casting is a series of processes that require precision and planning to ensure that design specifications are met every step of the way. From temperature and humidity control to dimensional checks and verifications, we have refined our process control system to produce the most consistent, cost-effective metal parts on the market today.
Quality at Every Step
Casting process control begins and ends with our process sheet, also known as the work construction. The process sheet assigns every product a part number, along with a list of operations that each part will undergo.
All PCT departments, from tool making to packaging, can refer to the process sheet to verify what actions were performed at previous stations and what is in queue. This internal checks and balances system produces the most consistent results with the highest levels of part-specific control.
3D modeling, either customer-submitted or in-house designed, is included with the process sheet to guarantee tooling accuracy. With over 35 years experience in tool making, PCT engineers are experts in gating tooling models with pinpoint precision. Samples are run to verify tooling accuracy. Visit our casting tooling page for additional information.
Our wax room is equipped with temperature and humidity controls to manage the consistency of our wax patterns. To avoid wax dimensional changes, we purchase wax exactly to our specifications. We adhere to all temperature tolerances outlined in the process sheet to eliminate wax expansion and contraction.
Once again, temperature and humidity are the focal point of our dip room process control. We use proprietary formulas for our slurries which are designed for maximum consistency. Each part has different dipping procedures, which are clearly outlined in the process sheet.
Computerized temperature controls are built into our dewaxing equipment. Our dewaxing equipment quickly ramps up to the temperature specified in the process sheet, holds that temp for a period of time, then ramps down.
The process sheet outlines part-specific pouring and shell temperatures, as well as solidification control techniques. Chemical analysis is performed at this station to verify the chemistry of the metal.
Here we perform blasting, grinding, and runner system removal from parts. Once again, the process sheet dictates information on part-specific blast types and gate grinding.
We can meet all heat treatment requirements, including MIL-H-6875. Please refer to our heat treatment page for more information on our heat treatment services.
Non-destructive testing Through a combination of in-house resources and outside vendors, we can meet any NDT specification. Our casting designers can also assist with developing part-specific NDT techniques.