Ledtiderna förinvesteringsgjutningkan variera avsevärt beroende på flera faktorer, inklusive komplexiteten i delen, materialet som används, mängden beställda delar och gjuteriets arbetsbelastning .
1. Design och mönsterskapande
Initial Design Phase: If the part is new and requires design from scratch, this can take anywhere from a few days to several weeks. In some cases, especially for highly complex aerospace or medical components, the design process may involve multiple iterations with the client and extensive computer - aided design (CAD) work. For example, designing a new turbine blade for an aircraft engine could take 2 - 4 weeks as engineers Optimera formen för aerodynamisk effektivitet och värmemotstånd .
Wax Pattern Making: Once the design is finalized, creating the wax patterns begins. For simple parts, the wax injection process can be relatively quick. If the part has a basic shape and the foundry has pre - made molds for similar designs, the wax pattern production for a small batch (say, 10 - 50 pieces) might be completed in 1 - 2 days. However, for intricate parts with fine details or internal cavities, each wax pattern may need to be carefully crafted. This could extend the wax pattern production time to a week or more for a small batch. Additionally, if cores are required to create internal features, the process of inserting and securing them within the wax pattern also adds to the time.
2. Keramisk skalförberedelse
Dipping and Laying-up Layers: The creation of the ceramic shell involves multiple dipping steps. Each dip is followed by a drying period. For a standard - sized part, the dipping process might take 2 - 3 days, with drying times between each dip adding another 1 - 2 days. In total, the ceramic shell preparation for a simple to moderately complex part can take around 3 - 5 days. However, for large or very complex parts, where more layers of the ceramic slurry are needed to ensure strength and dimensional accuracy, this process can take up to a week or even longer. For instance, a large, complex marine component with thick walls and detailed exterior features may require 7 - 10 days for the ceramic shell att vara fullt förberedd .
3. dewaxing och före uppvärmning
Dewaxing: The dewaxing process itself usually takes a few hours. Once the ceramic - shell - covered wax patterns are placed in the dewaxing furnace, the wax can be melted out within 2 - 4 hours, depending on the size of the patterns and the furnace's capacity. However, the setup time for the dewaxing process, including loading the furnace and ensuring proper temperature control, kan lägga till en annan 1 - 2 timmar .
Pre - heating the Shells: After dewaxing, the ceramic shells need to be pre - heated. This typically takes 1 - 2 days, as the shells need to be gradually brought up to the appropriate temperature to ensure proper metal flow during pouring. The pre - heating time can be longer for larger or thicker - walled shells, as they require more time to reach a uniform temperature i hela .
4. Metall häll och stelning
Pouring: The actual pouring of the molten metal is a relatively quick process. Depending on the size of the part and the pouring equipment, it can take anywhere from a few minutes to half an hour. For small parts, the pouring might be completed in 5 - 10 minutes, while for large, complex components, it could take 20 - 30 minutes. However, the Inställningar för hällning, inklusive att smälta metallen till rätt temperatur och förbereda den hällande sleven, kan ta flera timmar .
Solidification: The solidification time of the metal depends on the thickness of the part and the metal being used. Thin - walled aluminum parts may solidify within 10 - 15 minutes, while thick - walled steel or superalloy components could take several hours. For example, a large steel casting with a thickness of several inches might take 2 - 4 hours to fully stelna .
5. Post - Bearbetning och inspektion
Att slå ut och trimning: Efter stelning, att ta bort det keramiska skalet och trimning av granar och grindar kan ta 1 - 2 dagar för en liten sats med delar . Denna process kan innebära manuellt arbete såväl som användningen av mekanisk utrustning, och tiden kan öka om delarna har mycket intrikat områden som är svårt att få tillgång till.}
Finishing Operations: Finishing operations such as sandblasting, heat treatment, and machining can add significant time to the lead time. Sandblasting to remove any remaining ceramic material might take a few hours for a small batch, but heat treatment can take 1 - 2 days depending on the type of metal and the desired properties. Minor machining to achieve the final dimensions can also take 1 - 3 dagar, särskilt om snäva toleranser krävs .
Inspektion: Inspektionsprocessen, som kan inkludera visuell inspektion, dimensionella kontroller och icke -förstörande testning, kan ta 1 - 2 dagar . för högkvalitativa kritiska komponenter, såsom de som används i flyg- och mer omfattande inspektionsförfaranden kan vara i plats, vilket förlänger inspektionstiden till {{4} .}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}})
6. övergripande ledtider
Små, enkla delar: För små, enkla investeringar - gjutna delar i små mängder (10 - 50 delar) kan den totala ledtiden från designgodkännande till färdig produkt vara så kort som 2 - 3 veckor om gjuteriet har befintliga formar och en relativt lätt arbetsbelastning .
Medelstorlek, måttligt komplexa delar: För medelstora delar med måttlig komplexitet (E . G ., en typisk bilmotorkomponent), är ledtiden vanligtvis 4 - 6 veckor . Detta inkluderar tid för designmodifiering om det behövs, vaxproduktion, ceramisk skal, mallkärl, metall, metall, post - process och process - Processing, och Processing, och Processing, och Processing, - Processing, - Processing, - Processing, - Processing, Inspektion .
Stora, mycket komplexa delar: För stora, mycket komplexa delar, såsom de som används i flyg- eller kraftproduktion, kan ledtiden vara 8 - 12 veckor eller till och med längre . dessa delar kräver ofta mer detaljerat designarbete, längre keramiska skalberedningstider och mer omfattande post -bearbetnings- och inspektionsförfaranden .}}
In recent years, some foundries are adopting new technologies to reduce lead times. For example, the use of 3D printing for wax pattern or ceramic shell production can significantly shorten the time for pattern creation and mold preparation. In cases where 3D - printed wax patterns are used, the lead time for small, complex parts can be reduced by 1 - 2 weeks compared to traditional wax injection Metoder .