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investment casting
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investment casting

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investment casting, 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.

Diagram of a zinc-lead blast furnace system showing ore and coke entering through charge hoppers, with labeled furnace, air preheater, blower, taphole for slag and lead bullion, and a connected lead-splash condenser using rotors to separate and cool lead and zinc, with pathways for molten metals and off-gas.
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metallurgy: Investment 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.

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In modern foundries, plastics, 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.