Non-Ferrous

Investment Casting

GROUP 3
 Introduction
Non-Ferrous Investment
Casting
Non-ferrous investment casting, shaping metal
objects with non-iron alloys using molds, finds extensive
application in aerospace, automotive, medical, and various
industries, thanks to its precision and versatility in crafting
intricate components. This overview aims to comprehensively
highlight the importance, applications, and anticipated future
trends of non-ferrous investment casting.
 Brief History
As the first metals used by humans for metallurgy, non-ferrous metals have a rich
history. Early humans were attracted to these metals because they hardly corrode.

One of the first non-ferrous metals discovered by man is copper, and this signaled
the start of the copper age. Furthermore, in order to make maximum use of this metal, humans
had to learn the art of forging and molding. The low melting point and ease of fabrication made
copper man’s metal of choice. The Bronze Age swiftly followed the Copper Age when humans
discovered they could alloy copper with tin to produce bronze.
 Brief History
Humans have used non-ferrous metals for a longer period than their ferrous
counterparts. As a matter of fact, around 5000 BC humans developed a technique used to
make bronze. This technique involved smelting and alloying copper with other metals like tin
and arsenic. The onset of this smelting and the alloying period ended the stone Age, marking
the beginning of the Bronze Age.

Other non-ferrous metals discovered are gold and silver. These metals took the
place of wood and stone as human ornaments. However, since these metals are rare, they are
used to manufacture luxury items.

Today, we use non-ferrous metals to make tools, vehicle engines, pipelines, cutlery,
electrical cables, ornaments, and many more.
 II. Fundamentals of Non-Ferrous Investment Casting
A. Investment Casting Process
Die casting is a metal casting process that involves forcing molten metal into a mold cavity
under high pressure. The basic steps in die casting include:

Step 1: Mold Preparation - The die casting process begins with the preparation of the mold, which is
usually made of two steel dies. These dies are designed to create the desired shape of the final
product.

Step 2: Melting - The chosen metal, often an alloy, is melted in a furnace to achieve the necessary
consistency for casting. The temperature is closely monitored to ensure proper flow and quality.

Step 3: Injection - The molten metal is injected into the mold cavity under high pressure. This pressure
helps fill the mold quickly and reduces the formation of voids or defects.
A. Investment Casting Process

Step 4: Cooling - After injection, the molten metal in the mold cools and solidifies. The cooling time is
critical for the final product's properties and structural integrity.

Step 5: Ejection - Once the metal has solidified, the two halves of the mold are separated, and the newly
formed part is ejected. Ejection pins or mechanisms help release the casting from the mold.

Step 6: Trimming and Finishing - The cast part may have excess material or flash, which is removed
through trimming. Additional finishing processes, such as machining or surface treatments, may be
applied to meet specific requirements.
A. Investment Casting Process

Step 7: Quality Control - The finished parts undergo inspection to ensure they meet quality standards.
This may involve dimensional checks, visual inspections, or other testing methods.

Step 8: Recycling - Scrap material from the casting process, such as excess or defective parts, can often
be recycled and reused in the melting stage, reducing waste.
II. Fundamentals of Non-Ferrous Investment Casting
● B. Distinction between ferrous and non-ferrous materials:

- Ferrous materials contain iron, while non-ferrous materials do not. Non-ferrous alloys
include aluminum, copper, and titanium, offering unique properties.

● C. Key characteristics of non-ferrous alloys used:

- Non-ferrous alloys exhibit properties such as lightweight, corrosion resistance, and high
strength, making them ideal for various applications.
 III. Advantages Of Non-ferrous Investment Casting
A. Improved corrosion resistance

Non-ferrous investment casting offers several advantages, including improved corrosion

resistance due to materials like aluminum, brass, or bronze being less prone to rust.

B. Enhanced strength-to-weight ratio

Enhanced strength-to-weight ratio is achieved as these materials can provide high strength
without excessive weight, making them suitable for various applications.
 III. Advantages Of Non-ferrous Investment Casting
C. Complex geometries and fine details achievable

The process allows for complex geometries and fine details, enabling intricate designs that
may be challenging with other manufacturing methods.

D. Cost-effectiveness and material efficiency

Cost-effectiveness is achieved through reduced material waste, as investment casting

minimizes the amount of excess material compared to traditional machining.
 IV. Application Of Non-ferrous Investment Casting
Aerospace and aviation

Aerospace castings are

utilized for designing small and large
aviation components for the industry.
These castings are suitable for both
either commercial or military sector
especially for fighter planes. The quality
castings are highly affordable and assure
maximum results for the industry.
 IV. Application Of Non-ferrous Investment Casting
Automotive manufacturing

Automotive Applications. In the

automotive industry, investment casting is
a versatile manufacturing process used
for creating a variety of intricate
components. For instance, it is
extensively employed in engine
production, where it fabricates parts like
pistons, cylinder heads, and crankshafts.
 IV. Application Of Non-ferrous Investment Casting
Medical device production

Produces a smooth surface

finish along with the ability to achieve
tight tolerances. It is ideal for intricate
designs and offers the consistency
needed for medical device applications.
V. Materials Selection and Alloy
The investment casting process is capable
of producing parts to tight specifications using a wide
range of ferrous and non-ferrous alloys that are
melted and poured into a ceramic mold. Material
choice is typically performance-driven based on the
application design requirements, though the most
common investment casting alloys include Stainless
Steel and Aluminum.
A. Overview of common non-ferrous alloys
Aluminum Lead Brass

Tin Magnesium Molybdenum

A. Overview of common non-ferrous alloys
Cobalt Copper Titanium

Nicke
Bronze Zinc
l
A. Overview of common non-ferrous alloys
Gold Silver Carbon Steel

Stainless Steel
B. Factors influencing material selection:
- Considerations include mechanical properties, cost, and environmental factors, tailored to
the requirements of the application.

Factors Influencing Material Choice:

 Properties: Material properties like hardness, strength, heat resistance, and corrosion
resistance should align with application needs​​.
 Cost: Material cost varies; superalloys can be expensive, while carbon steel and
aluminum may be more cost-effective​​.
 Machinability: Ease of machining varies; aluminum alloys are generally easier to
machine than stainless steel​​.
 End-Use Environment: The environment where the product will be used plays a crucial
role in material choice, especially concerning corrosion resistance​​.
C. Considerations for specific applications:
- Material selection is crucial in meeting performance requirements and ensuring
durability in diverse applications.
VI. Quality Control and Testing
A. Inspection methods in non-ferrous investment casting:
- Utilizes methods like X-ray, dye penetrant, and visual inspection to ensure components
meet specified quality standards.

Examples are:

 X-ray – In this method, a casting is exposed to

radiation from an x-ray tube. Any hole, crack or
inclusion that is less dense than the casting
alloy is revealed as a dark area.
 Dye-Penetrant - penetrant testing, also
known as liquid penetrant inspection, is used
in precision investment casting to detect
surface-breaking defects.

 Visual Inspection – This method uses the

human eye to identify surface defects, cracks,
gas evolution, slag or sand inclusions,
misruns, cold shuts, and molding flaws.
B. Ensuring dimensional accuracy and surface finish:
- Rigorous quality control measures are implemented to guarantee precise dimensions
and desired surface finishes.

C. Compliance with industry standards and certifications:

- Adherence to standards such as ISO and ASTM ensures the reliability and safety of non-
ferrous cast components.
VII. Challenges and Solutions
A. Potential issues in non-ferrous casting:
- may include porosity, shrinkage, etc.

• Porosity – is among the most

common casting defects. It occurs
when a pocket forms due to air or gas
trapped in the metal during
solidification.
 Shrinkage – is a cavity or depression in
castings that occurs as the material
cools to become solid.

B. Solutions for overcoming challenges:

• Employing advanced casting techniques
• process optimization, and
• quality control measures help address and mitigate potential challenges.
X. Conclusion

Key points:
Non-ferrous investment casting, employing alloys such as aluminum and
copper, relies on the precise technique of investment casting. Applied extensively in
aerospace, automotive, medical, and various industries, this method presents benefits
like corrosion resistance and intricate design capabilities. The focus is on delivering a
thorough comprehension of non-ferrous investment casting, encompassing its basics,
advantages, applications, and future trends.
X. Conclusion

Non-ferrous investment casting's pivotal role in the future:

Non-ferrous investment casting holds a crucial position in pivotal industries
like aerospace and automotive, ensuring its continued significance. The future trajectory
of non-ferrous casting is being influenced by ongoing technological advancements,
including 3D printing and sustainable practices. Its importance is underscored by its
contribution to the production of lightweight, durable, and intricate components, aligning
with the evolving requirements of diverse industries.
Thank You !!!
MEMBERS
:
Halog, Arica Catumber, Rainniel
Eroles, Christopher De Sosa, Rhenzo
Fronda, Joyce Dondonay, Ricky
Nadine Gural, John Jayven
Cesa, Art Jayvie Rusaban, Jerwin
Nogueras, Chris Morales, Nikzon
Nuestro, Hedcel Zapanta, Michelle
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Resources
● https://www.epcast.com/casting-materials
● https://www.linkedin.com/pulse/mastering-material-choice-investment-casting-guide-optimal-
%E6%B5%B7%E6%B1%9F-%E6%9D%A5-hynhe?trk=article-ssr-frontend-pulse_more-articles_related-
content-card
● https://www.wbcastings.com/blog/foundry-casting-inspections/
● https://precise-cast.com/quality-inspection/
● https://www.tpcastings.com.au/how-temperature-factors-affect-non-ferrous-metal-castings.html
● https://www.twi-global.com/technical-knowledge/faqs/ferrous-vs-non-ferrous-metals#:~:text=The
%20difference%20between%20ferrous%20and,they%20are%20most%20suited%20for.
● https://www.twi-global.com/technical-knowledge/faqs/what-metals-are-non-ferrous
● https://www.investmentcastchina.com/investment-casting-applications/#:~:text=1.,%2C%20cylinder
%20heads%2C%20and%20crankshafts.
● https://www.epcast.com/medical-equipment-devices#:~:text=Investment%20casting%20is%20an
%20excellent,needed%20for%20medical%20device%20applications.
● https://www.rapiddirect.com/blog/what-is-non-ferrous-metal/
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