Investment Casting FAQs

Investment casting is an industrial process based on and also called lost-wax casting, one of the oldest known metal-forming techniques. From 5,000 years ago, when beeswax formed the pattern, to today’s high-technology waxes, refractory materials and specialist alloys, the castings allow the production of components with accuracy, repeatability, versatility and integrity in a variety of metals and high-performance alloys. Lost foam casting is a modern form of investment casting that eliminates certain steps in the process.

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The process is generally used for small castings, but has been used to produce complete aircraft door frames, steel castings of up to 300 kg (660 lbs) and aluminum castings of up to 30 kg (66 lbs). It is generally more expensive per unit than die casting or sand casting but has lower equipment costs. It can produce complicated shapes that would be difficult or impossible with die casting, yet like that process, it requires little surface finishing and only minor machining.

Sand Casting
Investment Casting has improved surface finish, more precise, tighter tolerances, greater design capability and greater alloy choices.

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Forging
Investment Casting allows for greater design freedom equating to more complex geometries.

MIM
Investment Casting has lower tooling costs, is capable of producing larger parts, has lower alloy costs and can economically produce smaller run quantities.

Machining
Investment Casting offers material and labor savings for each required part.

Previously Asked Questions:
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Beryllium Copper Alloy (4/5/)
We have been asked to quote a job in Beryllium Copper and have no experience with it.  From the limited information I've found online, it seems like there are significant challenges associated with casting it.  I am hoping to discuss these challenges with somebody that has experience with it.
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Alloy Certifications Specifications (3/27/)
I am about to purchase some steel investment castings from a foundry, and I was just wondering, what are the typical certification specs that I can request from them?
Such as: adhering to ASTM A732, or ISO____, or porosity limits, or chemical/mechanical test reports, or defect free reports?
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Foundry Dictionary  (03/01/)
I am a student in a French engineer school.  We address many subjects having the need of TOEIC English language proficiency test, however we don't have a professional English class which addressed foundry terms.
So I would like to create a specific dictionary with all regional synonyms, providing a good translation.
Currently, I use "Foundry Dictionary", an application on Playstore.  It is very good and there are many definitions but it is not really complete, nor is it available in print or pdf.
Additionally, I would like to categorize each word for easier search. For example, shrinkage is a defect and sprue is a casting device.
Do you know of such a work? If not, do you know someone who would be willing to help me?
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Non-HAPS Flux for Aluminum Melting (01/14/22)
The Air Quality department of our state is questioning whether the flux used at our foundry contained any hazardous materials.  Who can I speak to about getting a non HAP's flux for aluminum melting?  Typically, we use about 10 cups per year.
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​Slurry Viscosity Measurement (10/20/21)
We are having inconsistency measuring viscosity using the viscosity cup.  Currently, we do the cup test every 2 hours and the plate weight once a shift.  We are considering eliminating the viscosity cup test and do plate weight test every 2 hrs..  Is there a reason one would not want to only measure the plate weight?
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3D Printer (10/06/21)
We need a 3D printer with the capacity to produce models up to 300mm. Please advise.  
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Standards Addressing Porosity in Investment Casting (07/28/21)
We are in the process of trying to locate some governing standards (such as ASME, ASTM, etc.) that address the issue of porosity in investment cast components.  I was wondering if you could point me in the right direction.
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Material Handling - Powders and Sands (06/29/21)
What is the industries preferred way of handling materials when it pertains to; lifting or moving 50# bags of sand and powders?
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Metal Specifications (04/19/21)
I am a metallurgy and materials engineer, I have been working in an investment casting foundry as a production manager for about 2 years. Is there a standard accepted source on ICI metal specifications? and this resource should include chemical analysis and heat treatment and mechanical properties of the material.
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Investment Casting Manganese Material(W.Nr.1.) (Mn12) (03/22/21)
A customer has placed an inquiry for parts cast in manganese alloy (W.Nr.1.).  We are unfamiliar with this alloy and would like to know if it is cast-able using the investment casting process and are there aspects of casting this alloy of which we should be aware. Could the ICI please off some guidance in this area?
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Pouring Temperatures (03/02/21)
I am trying to compile a chart for my boss about the necessary melting and pouring temperatures for specific grades of metals and I was wondering if you would have a good idea of resources to look up this information easily. I have tried looking through the ASTM Standards book as well as looking for resources online with not much to show for it and it would be a great help in building this chart to help our foundrymen. Thank you for your time and input. 
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Aluminum Test Bars (01/13/21)
I hope you can direct me to someone within your institution willing to share some advice on investment aluminum test bars. We have been experimenting here and are getting mixed results.  I have reviewed the technical paper "The Effects On The Mechanical Properties When Using Different Geometry Testbar Coupons."
Per this technical paper, we ran several 1/4" diameter test bars out of 356-T6, with a pour temperature of deg F. and a mold temperature of 995 deg F., but we are experiencing strange results are within the same tree. We had bars pass comfortably and also fail miserably (very low elongation). The entire tree was heat-treated intact before the test bars are removed.
 I did review the ask an expert question, "Improve Mechanical Properties of A357/A356/C355 Aluminum Castings (3/27/19)" We do add Tibor to our melt but not directly in the ladle like your answer suggested.
I have attached a couple of pictures showing our test bar shape and gaiting. We were concerned with the sharp radius of the end of the test bar, so we experimented with a few different shapes with no success.
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