Ceramic Cores for Forming Cavities Too Small or Complex for Investing Casting

Ceramic cores are sacrificial ceramic structures mainly used for creating cavities that are too complex or small to be machined within investing casting processes. These cores are mostly found in aerospace and industrial markets but there is an increasing demand in the sports, healthcare and automotive markets.

Ceramic cores are created using a porous ceramic material made up of many compositions of alumina, silica and zircon. The composition of Morgan Advanced Materials’ blends can be customized to the individual requirements of customers.

Morgan Advanced Materials’ compositions allow for there to be minimal interaction between the core and the metal that will be used in the casting process. The low coefficient of thermal expansion ensures the core remains dimensionally stable when the molten metal engulfs it during the casting process. The stability of the compositions at high temperatures is very vital as they allow for Morgan to manufacture ceramic cores to the tolerances that are required by the customer.

This makes their products more precise than competing casting approaches such as sand casting. The materials used to make their cores are also somewhat porous making it easier for them to be leeched out by chemicals, leaving behind the preferred cavity.

The type of alloy being cast is also important: ceramic cores can be used with a broad range of alloys, including nickel and cobalt-based alloys, aluminium, steels, and titanium, but the match between ceramic and alloy must be suitable. The complexity and size of the item being cast will also impact the ceramic core selection.

Morgan Advanced Materials’ ceramic cores display the following key features and benefits:

Features

  • Cores are made from materials possessing very low coefficients of thermal expansion, a very desirable property for investment casting
  • Products are also easy to leech out through chemical reactions
  • Specialise in water removable ceramics which do not require chemical leeching but can be removed using pressurized water

Benefits

  • Cores can be manufactured in different strengths based on the customer’s requirements. Strong and very weak structures can be manufactured, thus providing the customer with no restrictions on their design
  • Parts can be processed with tolerances down to 0.05 mm and thicknesses less than 0.3 mm
  • X-Ray capability is available if needed to verify perfection internally and externally
  • The material/core is thoroughly tested and each core goes through internal and external trials
  • Their advanced materials display high temperature stability in thick sections which hold up to the latest super alloy used in current advanced gas turbine jet engines

Morgan Advanced Materials’ commitment to high quality standards together with their well renowned research and development into ceramic materials guarantees that their cores are the right choice for many markets including industrial, healthcare, automotive, aerospace and sports.

Morgan Advanced Materials Certech has 45 years’ experience in the design and production of multifaceted ceramic cores and wax patterns for demanding industrial casting applications globally.

Morgan Advanced Materials’ cores are an important component in the manufacture of intricate castings for aircraft engine turbine blades, vanes and related cast components. They can also be used to create a variety of products from valve components to industrial turbine blades, to create features and cavities with precision, and at the same time as lowering the costs of machining parts.

The injection moulded ceramic cores can also be employed within the automotive industry in order to substitute sandcasting processes where necessary. Sandcasting approaches are not as accurate, in terms of tolerances, as ceramic cores and do not provide a smooth finish on the end product. These two key issues can be eradicated easily with the use of ceramic cores.

There is also an increasing demand for ceramic cores within the healthcare sector with the aim of casting orthopaedic instruments and dental equipment.

So, why should one use the Certech range of cores for the next project?

Morgan Advanced Materials offers core preparation and coating methods to further strengthen the customer’s core:

  • These include KR 1, a water-based resin which reinforces the core for Wax Injection operations
  • Urea treatment which additionally strengthens cores for the casting process is available in the UK
  • Alumina coatings are also available so as to minimise the metal interaction between the core and the customer’s casting

Morgan Advanced Materials is also the leader in R&D within the ‘Additive Manufacturing’ sector with a main interest in the development of 3D printing methods.

  • The company’s global facilities offer large capacity for complete outsourcing and assembly
  • Enhanced casting yields using their ceramic core and wax products
  • They offer full inspection services ensuring the final product is completely optimised for a particular application
  • They can create complex, intricate voids with very thin trailing edges
  • Short lead-times (minimum turnaround for wax injections produced in the UK)
  • They can trial wax pattern dies to guarantee they get it right first time (UK)

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