Ceramic casting

At the forefront of casting technology, Norton Cast Products has invested in ceramic casting technology in response to the specialised requirements of our customers. Ceramic casting is a highly technical process that can be used to produce impellers, diffusers and other complex shapes in various grades of nickel alloys, cobalt alloys, stainless steel and carbon steel casting.

The ceramic method of Mould and Core manufacture produces a dramatically improved surface finish resulting in improved hydraulic efficiencies. Ceramic casting offers several advantages, including the ability to produce complex shapes with fine details, excellent surface finishes, and a wide range of ceramic materials with varying properties. It is often used in industries such as aerospace, automotive, electronics, and art to manufacture components that require high precision and intricate designs.

The ceramic casting process

  • Pattern Creation

    A pattern, often made of wax or a similar material, is produced to replicate the desired shape of the final ceramic object. The pattern can be created by hand or using computer-aided design (CAD) software and 3D printing.

  • Mould Production

    The pattern is then embedded in a material called investment, which is a refractory material capable of withstanding high temperatures. The investment material is usually a mixture of fine ceramic powders, such as silica, zircon, or alumina, suspended in a binder. The investment material is poured around the pattern and allowed to harden, forming a ceramic mould.

  • Pattern Removal

    Once the investment material has solidified, the mould is heated to melt or burn out the pattern. This leaves behind a cavity in the mould that matches the shape of the original pattern.

  • Ceramic Pouring

    The ceramic material, typically in a liquid or slurry form, is poured or injected into the mould cavity. The mould is carefully heated to encourage the ceramic material to solidify and take the shape of the mould.

  • Cooling and Solidification

    The ceramic material is allowed to cool and harden within the mould. This can be done by controlled cooling or by placing the mould in a furnace.

  • Mould Removal

    After the ceramic material has solidified, the investment mould is broken or dissolved away to reveal the final ceramic object. This can be done mechanically, through vibration or water blasting, or chemically with the use of solvents.

  • Finishing

    The ceramic object may require additional finishing processes, such as sanding, polishing, or glazing, to achieve the desired appearance and surface quality.