Flow modelling optimises investment casting

Morgan Technical Ceramics, Certech, has pioneered a new flow-modelling technique for designing ceramic cores used to manufacture parts for the aerospace, automotive and medical markets.

The use of the software is a major breakthrough for the investment casting process and will optimise injection moulding of ceramic cores and enable the design of parts with more complex geometries.

While flow-simulation software is commonly used throughout the plastics-manufacturing industry, to date it has not been used by the ceramics industry in this way.

Morgan Technical Ceramics has been innovating and investing in the software for the past 12 months and is now working closely with its customers to enhance the design and manufacturing process of their products.

By using the software, Morgan Technical Ceramics' specialists can accurately predict how the ceramic core cavity will fill.

Any areas of stress and potential breakage are highlighted early in the manufacturing process.

The design of the core can then be refined to ensure it is filled in a controlled and uniform way, which improves the quality of the finished ceramic core and consequently the metal casting.

The whole process is more efficient than traditional methods because simulation is carried out before any metal is cast, saving time and resources.

Through better understanding of the way ceramic flows during injection moulding, engineers can design higher-performance parts with more complex geometries: for example, turbine blades for aircraft engines or industrial gas turbines used in power generation.

Tolerances of up to +/-0.1mm can also be achieved.

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