Water glass casting, also known as sodium silicate casting, is a casting process akin to investment casting, employing water glass as the binding material for the shell used in casting.

This method offers superior surface finish and dimensional precision compared to sand casting, and it is particularly well-suited for creating complex shapes.

Water glass casting is especially cost-effective and finds extensive use in the production of steel and iron components.

Origins and Prevalence of Water Glass Casting

Water glass casting technology originated in Russia and has now become one of the most common investment casting processes in China.

Approximately 75% of foundries in China specialize in water glass casting, with the remaining focusing on silica sol casting.

Advantages of Water Glass Casting

Omicron Casting is a trusted water glass casting manufacturer and supplier with substantial experience in producing water glass components.

The key benefits of the water glass casting process are as follows:

• Superior surface finish compared to sand casting.
• Enhanced dimensional precision when compared to sand casting.
• Ability to produce more complex parts.
• Suited for larger parts compared to traditional investment casting.
• Cost-effective compared to investment casting.
• Shorter lead times than investment casting.
• A wider choice of metals.
• Environmental advantages, as the wax used is entirely recyclable.

Water Glass Investment Casting Process

The main distinction between the lost wax method and water glass casting lies in how the wax is removed from the ceramic mold:

• Investment casting employs high-temperature autoclaves to melt the wax.
• Water glass casting submerges the molds in hot water to remove the wax. The melted wax floats on the water’s surface and can be skimmed off and reused for wax-making.

Key Steps in the Water Glass Casting Process

1. Wax Injection: Melted wax is injected into molds to create wax patterns of the desired castings. Wax molds, typically made of aluminum, account for shrinkage in both the wax and metal used. Wax tooling can range from simple two-piece dies to more complex dies with water-soluble or ceramic cores.
2. Wax Assembly: After the wax patterns cool and stabilize in size and shape, they are mounted onto a sprue or tree made of wax. The sprue contains gates, runners, and supports to ensure proper feeding during the casting process.
3. Shell Making: The wax sprue is invested in ceramics to create molds for pouring the metal. The ceramic consists of a liquid slurry covered with dry sand. Layers of slurry and sand are applied to each sprue until the ceramic shell is thick enough to withstand the casting process. This shell-building process typically takes one day, with an additional 2 days to nearly a week for the shells to dry completely.
4. Dewaxing: Once the ceramic shells are dry, they are fired to eliminate any residual wax and cure the ceramic shell, making them ready for casting.
5. Pouring: The processed shells are preheated in an oven before casting. Once at the appropriate temperature and with the molten metal prepared and qualified, the shells are removed from the oven, and the metal is poured into them.
6. Finishing: The finished casting is obtained by hammering, media blasting, vibrating, waterjet cutting, chemical dissolution (sometimes with liquid nitrogen), or grinding. The sprue is cut off and recycled. Further cleanup may be necessary to remove any signs of the casting process.

Omicron Casting’s Water Glass Casting Parameters

• Applicable Materials: Cast steel, cast iron, stainless steel, nodular cast iron, high chromium iron, high manganese steel, alloy steel, non-ferrous steel alloy, heat-resistant steel.
• Material Standards: GB, ASTM, AISI, DIN, BS, JIS, NF, EN, AS, ARR.
• Weight Range: 0.02 kg – 50 kg.
• Tolerance: CT 5~7.
• Surface Roughness: Ra 6.3.
• Annual Output: 1200T.
• Applications: Auto, motorcycle, valve, marine, machine tools, hardware, railway, gear, impeller, pump, reducer, motor, mining machinery, engineering machinery, transmission machinery, forestry machinery, communal facilities, and more.
• Drawings Software: Pro/E, AutoCAD, SolidWorks, CAXA UG, CAD/CAM/CAE.
• Machining: Turning, milling, drilling, grinding, threading, NC, etc.
• Finishing: Sandblasting, polishing, plating, acid treatment, anodizing, painting, etc.

Why Choose Water Glass Casting with Omicron Casting?

Water glass casting, while less common in some countries, has gained prominence in China.

Approximately 75% of Chinese foundries specialize in water glass casting due to its advantages in material cost and shorter production cycles.

This process has been pivotal in civil machinery manufacturing.

By adding 0.5% penetrant, the surface quality of water glass casting can be significantly improved, approaching the surface finish achievable with silica sol casting technology.

This modification helps eliminate defects associated with traditional shell-making techniques and improves the working environment.

Moreover, the water glass casting process boasts simpler and less stringent process parameters and operational requirements, making it accessible to general workers with short training periods.

This reduces dependence on highly skilled workers, stabilizes production efficiency, and decreases production costs.

Applications of Water Glass Casting

Water glass casting is primarily used for larger and more complex-shaped products in fields such as trailers, agricultural machinery, and the offshore industry.

It excels in providing superior surface finish and dimensional precision compared to sand casting and accommodates various materials, including regular iron.

Contact Omicron Casting

For more information about Omicron Casting, obtaining a quote, or discussing your water glass casting project requirements in detail, please contact Omicron Casting through the provided contact information.

They are committed to delivering reliable solutions tailored to your needs.