Internship Report
Internship Report
Investment Casting
A PROJECT REPORT
Submitted by:
Bakarniya Dhara Kalubhai
210200119014
In partial fulfillment for the award of the degree of
BACHELOR OF ENGINEERING
in
Mechanical Engineering
Government Engineering
College, Rajkot
DECLARATION
I hereby declare that the Internship / Project report submitted along with the Internship
the supervision of Prof. R. B Raval and that no part of this report has been directly
copied from any students’ reports or taken from any other source, without providing
due reference.
Acknowledgement
I would like to express my sincere gratitude to everyone who has contributed to the
First and foremost, I extend my deepest appreciation to my internship supervisor for their
unwavering support, guidance, and valuable insights throughout this period. Their expertise
of the intricacies of investment casting. I am also grateful to my mentor and colleagues for
their mentorship and for providing me with hands-on experience that has enriched my
learning. Their patience and encouragement have been crucial in helping me overcome
challenges and gain practical skills. Special thanks go to the entire team at the Investment
Casting Faculty for their warm welcome and collaborative spirit. Their collective efforts
have created a conducive learning environment where I felt motivated and inspired to excel.
I would like to acknowledge my institution for offering me this internship opportunity and
Lastly, I am profoundly thankful to my family and friends for their unwavering support and
source of motivation.
This internship has been an invaluable experience, and I am truly grateful to everyone who
I
Gujarat Technological University GEC, Rajkot
Team ID:- 597339
Abstract
This report presents a comprehensive overview of the internship undertaken
at the Investment Casting Faculty. The primary objective of the internship was
to gain practical experience and deepen theoretical knowledge in the field of
investment casting. Throughout the internship, various aspects of the
investment casting process were explored, including wax pattern creation,
mould preparation, metal casting, and post-casting treatments.
The report also discusses the application of quality control measures and the
use of advanced technologies in enhancing the efficiency and accuracy of the
casting process. Additionally, it highlights the collaborative efforts within the
faculty that contributed to a supportive learning environment.
Overall, this internship has been instrumental in bridging the gap between
academic knowledge and practical application, equipping me with the skills
and experience necessary for a career in the investment casting industry. The
experience gained has not only enhanced my technical proficiency but also
provided a solid foundation for future professional endeavours in this field .
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Gujarat Technological University GEC, Rajkot
Team ID:- 597339
List of Figures
Fig 1.1 The Company .................................................................................................. 1
Fig 1.2 Pumps .............................................................................................................. 2
Fig 1.3 Impellers ........................................................................................................ 2
Fig 1.4 Orthopedic Implants ....................................................................................... 2
Fig 1.5 Industrial Valves ............................................................................................. 2
Fig 1.6 Critical Parts .................................................................................................... 3
Fig 1.7 Heating Furnace .............................................................................................. 4
Fig 1.8 Slurry Coating ................................................................................................. 4
Fig 1.9 Sand Coating ................................................................................................... 4
Fig 1.10 Mold Cooling ................................................................................................. 4
Fig 1.11 Spectrometer ................................................................................................... 7
Fig 1.12 Tensile Strength Testing ................................................................................. 7
Fig 1.13 Lab .................................................................................................................. 7
III
Gujarat Technological University GEC, Rajkot
Team ID:- 597339
List of Tables
IV
Gujarat Technological University GEC, Rajkot
Team ID:- 597339
Table of Contents
Acknowledgement .......................................................................................................... i
Abstract .......................................................................................................................... ii
List of Figures ............................................................................................................... iii
List of Tables ................................................................................................................ iv
Table of Contents........................................................................................................... v
Chapter 1 About the Company .................................................................................. 1
1.1 Introduction .......................................................................................................... 1
1.1.1 Scope of Work............................................................................................... 2
1.1.2 Industry Served ............................................................................................. 2
1.2 Production Capabilities ........................................................................................ 4
1.3 Quality Control .................................................................................................... 7
Chapter 2 Exploring the Stages of Investment Casting ........................................... 8
2.1 Wax Injection…………………………………………………………………….8
2.2 Pattern Assembly………………………………………………………………...8
2.3 Shell Building……………………………………………………………………8
2.4 Dewax Operation………………………………………………………………...9
2.5 Shell Preheating...………………………………………………………………..9
2.6 Metal Pouring……………………………………………………………………9
2.7 Gate/Riser Cutting………………………………………………………………10
2.8 Heat Treatment………………………………………………………………….10
2.9 Shot Blasting…………………………………………………………………….10
2.10 Finishing Operation……………………………………………………………10
2.11 Final Casting Inspection……………………………………………………….10
Chapter 3 Practical Insights and Learnings in Investment Casting ..................... 11
3.1 Objectives of the Internship………………………………………………..…...11
3.2 Overview of Investment Casting……………………………………………….11
3.3 Learning Experiences…………………………………………………………..11
3.4 Skills Developed……………………………………………………………….14
3.5 Challenges Faced………………………………………………………………14
3.6 Conclusion……………………………………………………………………..15
References................................................................................................................... 17
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Gujarat Technological University GEC, Rajkot
Team ID:- 597339 About The Company
1.1 Introduction
Amtech's lettered and expert metallurgical team works from state-of-the-art spectrographic
and laboratory facilities to make sure quality control, design optimization, testing and
chemical report for allied quality. Our sales staff are qualified and experienced to assess
your requirements and ensure that the process, material and design are appropriate to your
needs.
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Gujarat Technological University GEC, Rajkot
Team ID:- 597339 About The Company
• Pump Parts
• Submersible Pump Parts
• Industrial Valve Parts
• Component Cast with Ceramic Core
• Automative Components
• Railway Components
• Lost foam Casting
• Medical Implants
• Hardware & Space Frame Components (Glass fitting spiders, Door handles, Heavy
duty locks)
• Textiles Machine Components
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Gujarat Technological University GEC, Rajkot
Team ID:- 597339 About The Company
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Gujarat Technological University GEC, Rajkot
Team ID:- 597339 About The Company
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Gujarat Technological University GEC, Rajkot
Team ID:- 597339 About The Company
We also do have all the in house facilities to checks all incoming raw material like Waxes,
Colloidal Silica, Ceramic Stuco, Zr Sand, Zr. Flour. In same we do test like Sp. Gravity,
Gelling Test, Scratch Test, Sieve Analysis, Ph, Viscosity, Ash Content etc.From the testing
of incoming metals and the control of alloys, to constant manufacturing controls and non-
destructive testing, every step of the investment casting process is closely monitored and
recorded as per ISO 9001 systems.Our process ensures the production of world class
precision investment castings for our valued customer.
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GujaratFig 1.13 Lab University
Technological GEC, Rajkot
Team ID:- 597339 Exploring The Stages Of Investment Casting
The wax patterns are attached by the gate to a central wax runner system. The runner
system is called a sprue. Patterns, runners,
and pouring cup compromise the cluster or
tree. Radius is provided to all joints between
pattern and runner. Same checked thoroughly
before coating to avoid rejection due to sand
inclusions
The preheated shell is filled with molten metal by gravity pouring. As the metal cools, the
parts, gates, sprue, and pouring cup become one solid casting.
Investment casting is known for its ability to produce parts with excellent surface finish,
high dimensional accuracy, and complex geometries that would be difficult or impossible
to achieve with other casting methods. It is widely used in industries such as aerospace,
automotive, medical, and jewellery manufacturing for producing components that require
high precision and detail.
Investment casting is generally used for making complex-shaped components that require
tighter tolerances, thinner walls and better surface finish than can be obtained with sand
casting. The distinguishing feature of investment casting is the way the mould is made. A
pattern of the part is made with wax, which is then dipped into fine ceramic slurry that
contains colloidal silica and alumina. The mould is dried and heated inside an oven to melt
out the wax leaving behind a ceramic shell mould for casting. The investment casting
method, also called the lost wax process, is used for precision casting of aerospace
components such as gas turbine blades. The investment casting of aluminium alloys results
in lower strength than sand castings, but offers tighter tolerances, better surface finish and
the capability to produce thin-walled sections.
What I learned:
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Gujarat Technological University GEC, Rajkot
Team ID:- 597339 Practical Insights and Learnings in Investment Casting
Wax patterns are crucial in the investment casting process as they form the basis of
the final metal parts. I learned that the creation of these patterns involves several
steps:
• Injection Molding: Wax is injected into metal dies to create the desired
shape. This step requires precise control of temperature and pressure.
• Assembly: Individual wax components are often assembled into a larger,
more complex pattern. This might involve welding wax pieces together or
attaching them to a central wax tree.
I had the opportunity to work with the injection molding machines and assist in the
assembly of complex patterns. I also learned about different types of waxes used, such as
pattern wax and sticky wax, and their specific properties.
Risers and gates play a crucial role in ensuring the quality of the final cast parts.
• Risers: These are reservoirs that hold excess molten metal. They feed the
casting as it solidifies and shrinks, preventing voids and ensuring complete
filling of the mold. I learned to calculate the optimal size and placement of
risers to ensure efficient feeding.
• Gates: These are channels that direct the flow of molten metal into the mold.
Proper gating design is essential to control the flow rate and minimize
turbulence, which can cause defects. I assisted in designing gating systems
and learned about different gating techniques like bottom gating and top
gating.
Understanding the design and purpose of risers and gates helped me appreciate their
impact on the final product's integrity and quality
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Gujarat Technological University GEC, Rajkot
Team ID:- 597339 Practical Insights and Learnings in Investment Casting
Mold building is a critical step that requires precision and attention to detail:
• Shell Building: The wax pattern is repeatedly dipped into a ceramic slurry
and coated with fine sand. Each layer is allowed to dry before the next is
applied, building up a strong, heat-resistant shell.
• De-Waxing: Once the shell is complete, it is heated in an autoclave to melt
and remove the wax, leaving a hollow ceramic mold.
• Firing: The ceramic mold is then fired in a kiln to remove any residual wax
and harden the shell.
- The final stage involves the extraction and finishing of the cast parts:
• Breakout: Once the metal has cooled, the ceramic shell is broken away to
reveal the rough casting. I learned various techniques for shell removal,
including mechanical methods and high-pressure water jets.
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Gujarat Technological University GEC, Rajkot
Team ID:- 597339 Practical Insights and Learnings in Investment Casting
Working on the production floor, I witnessed the entire journey from raw material
to finished part. This experience highlighted the importance of each step in ensuring
the final product meets the required specifications and quality standards.
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Gujarat Technological University GEC, Rajkot
Team ID:- 597339 Practical Insights and Learnings in Investment Casting
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Gujarat Technological University GEC, Rajkot
Team ID:- 597339 Practical Insights and Learnings in Investment Casting
6. Time Management
3.7 Conclusion
My internship at the investment casting industry has been an invaluable experience that
significantly broadened my technical knowledge and practical skills. Through hands-on
involvement in the intricate processes of wax pattern creation, mold building, molten metal
generation, and parts production, I gained a comprehensive understanding of the precision
and expertise required in this field.
Reflecting on my time in the industry, I appreciate the dedication and meticulousness that
underpin the investment casting process. The knowledge and skills I acquired during this
internship have not only deepened my appreciation for the craft but also equipped me with
a solid foundation for my future career. I am grateful for the opportunity to learn from
experienced professionals and to contribute to meaningful projects, and I look forward to
applying these lessons in my continued professional journey
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Gujarat Technological University GEC, Rajkot
Team ID:- 597339
References:
https://www.sciencedirect.com/topics/engineering/investment-casting
https://www.amtechcast.com
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Gujarat Technological University GEC, Rajkot