Densen Precision Casting:Focus on Solutions for Valve And Pump Components

Stainless steel lost wax casting process analysis - the core technology of precision manufacturing

1. Mold Design and Wax Mould Reproduction

Digital modeling and mold processing: Relying on 3D modeling technology and CNC engraving equipment, combined with high-strength aluminum alloy or mold steel, accurate reproduction of the design details, the key dimensions of the wax mold error control in the range of ± 0.05mm.

Vacuum waxing process: vacuum waxing process is used to inject the wax into the mold.

Vacuum wax injection process: Vacuum wax injection equipment is used to inject the molten wax liquid (65-75℃) into the mold cavity, eliminating air bubble defects through the synergistic control of pressure and temperature, and the surface finish of the wax mold reaches below Ra0.8μm.

2. Shell mold preparation and dewaxing treatment

Composite slurry coating technology: use silica sol and zirconium powder / mullite powder to mix slurry, layer by layer coating the wax mold surface, forming 8-12 layers of high-strength ceramic shell, taking into account the high temperature resistance and air permeability.

High-temperature baking: the wax is removed from the mold by roasting.

High-temperature roasting and dewaxing: Wax is removed in the roasting furnace at 1200℃, and the wax recovery efficiency is more than 95%, which realizes the target of resource recycling and environmental protection.

3. Melting, pouring and finishing process

Vacuum induction melting: refining stainless steel raw materials through electric arc furnace, spectrometer real-time monitoring of alloy composition to ensure the purity of liquid steel (total impurities ≤ 0.03%), casting temperature is precisely controlled in the range of 1580-1620 ℃.

The casting temperature is precisely controlled in the range of 1580-1620℃.

Directional solidification process: Sequential solidification technology is adopted to reduce internal loosening and porosity defects, and the casting density is increased to more than 99.5%.

Optimization of post-processing: After mechanical shell vibration, sandblasting and heat treatment, the blank can directly enter the finishing process, reducing the machining allowance by 30%.

Silica Sol Casting process

The core of the process: silica sol is used as the binder, and the dense shell is formed through multi-layer dipping and coating of refractory paint, sand spreading and natural drying and hardening.

The process is based on the use of silica sol as a binder.

Advantageous characteristics:

High precision: surface roughness of castings can reach Ra3.2-6.3μm, tolerance grade CT4-6, suitable for thin-walled, complex hole structure.

High Temperature Resistance: The surface roughness of the casting can reach Ra3-6μm.

High-temperature resistance: the baking temperature of the shell reaches 950-1050℃, and the metal liquid has excellent repattern ability, which ensures that the castings have clear contours.

Environmental protection: no chemical hardener is required.

Environmental protection: no chemical hardener is required, the production process is pollution-free, in line with green manufacturing standards.

Environmental Friendly

Typical applications: high precision pump impellers, valve internals and other corrosion-resistant parts with high surface quality requirements.

Typical applications: high precision pump impellers, valve internals and other parts with high surface quality requirements.

Water Glass Casting Process

Process core: using water glass binder, through ammonium chloride/aluminum chloride catalytic hardening, rapid formation of multi-layer shell.

The process is based on the use of water glass binder.

Advantageous characteristics:

Economical cost: Material cost is more than 30% lower than silica sol, suitable for mass production of medium and large castings.

Cost Economy

Advantage of efficiency: short chemical hardening cycle, fast production pace, controlled delivery time.

The advantages of the product are as follows

Wide range of applications: Can produce medium-sized castings from 2 inches to 10 inches, meeting the needs of carbon steel and low alloy steel.

Typical Applications

Typical applications: valve housings, pipe connectors, and other cost-sensitive and moderately structured industrial components.

Core advantages of Densen Precision Casting--Focus on solutions for valve and pump components

1. Leading technology: full process control

Medium-temperature wax all-silicone sol process: for stainless steel, duplex steel and other difficult materials, casting 0.5-50kg complex parts, wall thickness tolerance ± 0.1mm, surface finish Ra ≤ 1.6μm.

Customized design capability: support integrated casting.

Customized design capability: support integrated casting (such as multi-cavity valve body), shaped runner design, reduce welding process, improve sealing performance and pressure resistance level (up to Class 600).

Customized Design Capability

2. Quality Control: Zero Defect Delivery Guarantee

Triple inspection system: X-ray flaw detection (detecting internal defects), 3D dimensional scanning (accuracy verification), and spectral analysis (material compliance) to ensure 100% compliance with international standards such as API 6D and ISO 5208.

Failure Analysis Laboratory

Failure Analysis Laboratory: Provide wear simulation and process optimization suggestions for key parts such as pump shafts and valve sealing surfaces, extending the service life of parts by more than 30%.

Failure Analysis Laboratory

3. Efficient production capacity: fast response to market demand

Intelligent production line: fully automatic waxing machine, robotic arm group tree equipment, daily production capacity of 2,000 pieces, support for small batch trial production (3-5 days) and batch delivery (20 days from order).

Vertical Integration Advantage

Vertical integration advantage: one-stop service from mold development to finishing, reducing customers' supply chain management costs.

4. Deep plowing in the industry: focus on the core components of pumps and valves

Valve components: ball valve body, gate valve shell, check valve spool, etc., high temperature (600 ℃), corrosion-resistant (316L/904L material), applicable to petroleum, chemical, electric power and other fields.

Pump parts: impeller, pump cover, shaft sleeve, etc., through CFD fluid simulation to optimize the structure, reduce turbulence resistance, improve pump efficiency by 5%-15%.

The pump components are optimized by CFD fluid simulation to reduce turbulent resistance and improve pump efficiency by 5%-15%.

Contact Densen Precision Casting today to customize your industrial solution!

Whether you need high-precision valve components or high-pressure resistant pump parts, Densen Precision Casting is your reliable partner with its proven lost wax process, strict quality control and efficient delivery capabilities.