FUPRESA S/A Project Manual 5th Edition - Aug / 2016

PROJECT MANUAL

5TH EDITIONAUG./2016A

DITIONDITIONDITION

FUPRESA S/A Project Manual5th Edition - Aug / 2016

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FUPRESA S/A PROJECT MANUAL 5th Edition - August 2016

SUMARY WHY TO USE INVESTMENT CASTED PARTS?................................................................ 3

1. Flexibility of Design .................................................................................................... 3 2. Improving properties through the alloy selection........................................................ 3 3. High dimensional precision ........................................................................................ 3 4. Best superficial finishing............................................................................................. 4 5. Time and money savings ........................................................................................... 4 6. Relatively low investiment in tooling........................................................................... 4 7. Agility and reliability in the parts “re-manufacturing” .................................................. 4 8. Minimum metal loss per part (Sustainability).............................................................. 4

CHARACTERISTICS OF AN INVESTMENT CASTED PART............................................. 5

1. Scope: ........................................................................................................................ 5 2. Terms and definitions: ................................................................................................ 5 3. What does it mean investment cast? ......................................................................... 5 4. General features of the investment casted parts:....................................................... 6 5. Typical applications of the investment casted parts: .................................................. 6

QUALITY OF THE PRODUCT............................................................................................. 7

1. Chemical Composition: .............................................................................................. 7 2. Mechanical and metallurgical properties: ................................................................... 7

2.1 - Hardness ........................................................................................................... 7 2.2 - Microstructure:................................................................................................... 8 2.3 - Internal sanity: ................................................................................................... 9

3. Superficial Quality: ..................................................................................................... 9 4. Operating Performance: ........................................................................................... 10

COMPETITIVE DIFERENTIAL - FUPRESA ...................................................................... 12

1. Injection: ................................................................................................................... 12 2. Molding:.................................................................................................................... 12 3. Dewaxing:................................................................................................................. 13 4. Calcination:............................................................................................................... 13 5. Metal fusion and mold filling by the CGP process:................................................... 14 6. Support to the development of the manufacturing process:..................................... 14 7. Support to the Client’s Product Engineering (CO-DESIGN)..................................... 14


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Chart 1: Chemical composition of the Investment Casted Alloys....................................... 15

1. Carbon and low-alloyed steels: ................................................................................ 16 2. Tooling steels (*) ...................................................................................................... 17 3. Stainless steels: Ferritic, Martensitic and Hardening by precipitation. ..................... 18 4. Austenitic Stainless Steels ....................................................................................... 19

Chart 2: Mechanical Properties .......................................................................................... 20

1. Carbon and low-alloyed steels ................................................................................. 21 2. Stainless steel: Ferritic, Martensitic and Hardening by precipitation. ....................... 22 3. Austenitic Stainless Steel ......................................................................................... 22

VDG – P690 - DIMENSIONAL TOLERANCES, SURFACE STATES AND ADDITIONAL FOR THE MACHINING...................................................................................................... 23

1. Definition and validity range ..................................................................................... 24 2. Purpose .................................................................................................................... 24 3. Dimensional precision .............................................................................................. 25

3.1 - Decrease and shrinkage.................................................................................. 25 3.2 Reference plans and points .............................................................................. 25 3.3 Shape and extraction inclinations ...................................................................... 26

4. Dimensional tolerances ............................................................................................ 27 4.1 Tolerances of the Linear Dimensional .................................................................. 27 4.2 Tolerances of the shape and position................................................................ 28 4.3 Tolerances of the Angle..................................................................................... 30 4.4 Radius of Curvature........................................................................................... 31 4.5 Dimensional tolerances for wall thickness ......................................................... 31 4.6 Dimensional tolerances for pre-manufactured parts to be casted and casted together ............................................................................................................................32

5. Superficial quality ..................................................................................................... 32 6. Additional for machining ........................................................................................... 32 7. Complementary indications and data ....................................................................... 33

7.1 Inner radii ........................................................................................................... 33 7.2 Outer radii and outer chamfer............................................................................ 33 7.3 Holes, blind holes, channels, grooves and cracks............................................. 33 7.4 ldentification of the casted parts ........................................................................ 33

8. Complementary Information ..................................................................................... 34


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WHY TO USE INVESTED CASTED PARTS?

1. Flexibility of Design Investment casted parts are the dream of the designers!

They present very few restrictions.

Investment casted parts offer a wide freedom in the metal alloy selection.

Investment casted parts offer a wide freedom to design complicated outer

setups and complex inner shapes otherwise impossible to be achieved by forging, casting

or machining starting from the bar.

2. Improving properties through the alloy selection The wide freedom in the metal alloy selection enables to select those alloys

most effective in enhacing the mechanical resistance, thus making feasible to reduce the

wall thickness, and consequently the weight of the part.

For instance, selecting a stainless steel alloy will enable to eliminate an

eventual surface treatment.

3. High dimensional precision

Narrow tolerance ranges are consistent when compared to the forging.

Once established and monitored through CEP, the manufacturing process hasl

no variations along the time, unlike what happens in other processes caused by the mold

and tooling wearing.

For the investment casted, the aluminum or steel injection molds, whenever

designed and manufactured following the best practices are not affected by the wax

injection even after manufacturing millions of parts.


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4. Best superficial finishing

The superficial finishing around 100RMS or 3Ra, or 25Rz is far greater than the

one attained by forging or casting.

It can be improved by the finishing by vibration in a ceramic-abrasive

environment.

5. Time and money savings Investment casted parts can eliminate the need for machining some

applications, or else reducing it in a considerable way in others.

Due to its geometrical flexibility, an adequately conceived investment casted

part can replace other metallic item where it is necessary the mounting by riveting or

welding of multiple stamped parts, machined, forged or casted.

6. Relatively low investment in tooling

For medium and large size series, the investment in tooling poses a not relevant

weight compared to the yearly supplying amount.

7. Agility and reliability in the parts “re-manufacturing” Even after a long of period of interruption, the production rebounding is quickly

performed due to the low set-up time, which is characteristic of the investment casted

process.

8. Minimum metal loss per part (Sustainability)

As there is not chip generation, withdrawal of burr or other similar operations

and the casting channels of investment casted parts are recycled, there is low waste of the

alloy, representing an important competitive differential to expensive metallic alloys.


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FEATURES OF AN INVESTMENT CASTED PART

1. Scope:

To define the features of investment casted parts in such extent as they to

comply with every quality and functionality requirements set by the client and with the

minimum manufacturing cost possible.

2. Terms and definitions:

Investment casted part (or investment casted): metallic part casted by the

Investment Casted process.

Despite their name, investment casted parts may weight dozens of kilograms.

3. What is investment casted?

It is a part manufactured from a model attained by wax injection into a metallic

mold.

The model is glued as many others in a wax channel to form a wax tree, which

is ceramic-coated to form a ceramic mold.

When the mold is dry, the wax is melted, the mold is calcinated at high-

temperature and then filled with a liquid metal.

After cooling, the ceramic is fragmented to attain a metal replica of the wax tree

from which the parts are extracted by cutting and then cleaned.

The foundry/attack channel is removed generating a metal copy of the wax

model.


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4. General features of investment casted parts:

They present quite complex geometries with a high level of quality, narrow

dimensional tolerances and a good superficial finishing.

They can be casted in a wide range of metallic alloys: aluminum, copper, cobalt,

nickel, titanium-based alloys and all the ferrous-alloy families: carbon steel, low-alloyed

steels, tooling steels, stainless steels, cast irons, etc.

5. Typical applications of investment casted parts:

Cargo and passenger transportation vehicles, machinery and mechanical

equipment, weaponry, valves and connections, orthopedic prostheses, among other

applications.


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QUALITY OF THE PRODUCT

1. Chemical composition:

Table 1 attached show the typical chemical composition of the investment

casted alloys.

In the event the client specifies any alloy produced by other processes, the

investment casted will be supplied in the alloy with mechanical properties more similar to

those of the original alloy.

Quantitative restrictions of the chemical compounds non-specified in Table 1

must be mutually agreed.

The analysis of the chemical composition may range as foreseen in the ASTM

A 703 – 07 rule.

2. Mechanical and metallurgical properties:

Mechanical properties (resistance limit, pouring limit and stretching) are

presented in Table 2 attached.

The mechanical properties are not routinely tested, unless specifically required

by the Client.

In this case, the costs of the assays will be charged separately.

2.1 - Hardness

When there is no Thermal Treatment specification, the parts will be supplied in

their raw fusion state.


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Whenever there will be requirements as to the level of superficial

discarbonation, it must be mutually agreed.

The minimum acceptable hardness range of the tempered and quenched

investment casted parts will be 5 Rockwell C points.

For parts with normalization or annealing treatment, the specification must have

maximum hardness instead of a specific range.

In general, the measurement of the hardness is used to control thermal

treatments according to the ASTM A 370 – 08 rule.

2.2 - Microstructure:

In the event a specific microstructure will be required, it must be mutually

agreed, and defined in terms of:

• Admissible discarbonation depth;

• Depth of the cemented layer, whenever applicable;

• Constituent phases, with indication of the predominance, whenever

applicable;

• Morphology (continuity, direction, distribution, shape and size of the

phases or eventual defects that may appear in the microstructure), whenever applicable;

• Hardness, with determination of measurement spots, method and

admissible ranges.


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2.3 – Inner Sanity:

It will be set a casting process able to produce parts with less than 10% inner

contraction porosity (inner voids) in any cross-sectional section of the part.

This can be verified by radiographic inspection during the development state of

the process.

Such contraction voids should not be present in areas where some previously

known subsequent machining visually discloses the defects.

Some limited amount of other type of inner defects, including gas bubbles, slag

particles, non-metallic inclusions or porosity can be found.

If those defects make impossible to use the part, inspection methods and

acceptance limits must be set upon mutual agreement.

3. Superficial Quality:

The investment casted parts must not have any cold laps, seams, visual cracks

or visual shrinkage.

In the case of parts manufactured in magnetizable alloys, an examination by

magnetic particles must be performed in the development stage of the process in order to

assure that the casting process is able to produce parts that will comply with the

requirement of functionality of the product.

• Positive Defects (high relief defects):

Due to the nature of the investment casted process, positive defects can be

randomly found.


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Unless when mutually agreed otherwise, the occurrence of such positives will

be limited to no more than 25x25mm, provided they do not interfere in the functionality of

the product.

Those defects that will be removed by a subsequent machining will be

considered acceptable.

• Negative Defect (visual pores):

Negative defects can also randomly occur.

Unless when mutually agreed otherwise, the occurrence of such negatives will

be limited to no more than 25x25mm, provided they do not interfere in the functionality of

the product.

• Round corners (incomplete):

The corners of the investment casted parts can be rounded with radius of up to

0.50mm.

Smaller radii must be mutually agreed.

4. Operating Performance:

Performance is a feature connected not only to the quality of the product, but to

its design and utilization as well.

The requirements of the minimum performance standards of the parts are not

applicable as such performance is not always predictable through the determination of

their chemical, physical or geometrical features.

The commitment will be limited to the chemical, physical properties and

geometrical features of the part within the quantified and measurable feasible limitations.


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Examples:

• The maximum machinability can be related to the hardness, chemical

composition and microstructure.

• The resistance requirement to corrosion under specific conditions can be

related to the chemical composition, the structure, thermal and superficial treatments.

• The wearing resistance follows the same principle: superficial features,

chemical composition, hardess and microstructure.


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COMPETITIVE DIFFERENTIAL - FUPRESA

TECHNICAL AND TECHNOLOGICAL RESOURCES APPLIED TO

ACHIEVE “EXTRA QUALITY” IN THE INVESTMENT CASTED PRODUCED BY FUPRESA

1. Injection: • Paste-like wax injection made by state-of-the-art imported injectors, with

full control under critical variables in the injection process;

• Injection molds manufactured in thermally treated duralumin, refrigerated

and with automatic extraction from the wax models;

• Mechanical templates to provide dimensional safety along the cooling

process of the injected models;

• Preventive strict and systematic maintenance of the injection molds;

• Controlling letters to monitor critical dimensional features – CEP;

• Strictly controlled environmental temperature.

2. Molding: • Every critical feature in the process monitored by the use of controlling

letters – CEP;


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• From the 3rd mud/refractory layer on, their application upon the use of 3

mechanical systems in handling the molds with command performed through CLP in order

to assure the sturdiness of the molding process;

• Chemical drying at each application cycle of the mud/refractory layer;

• Supervisory system of the environmental temperature and humidity

conditions – CEP.

3. Dewaxing: • Wax extraction by steam-supplied autoclaves generated in a gas boiler

with permanent monitoring of the filling and unloading times of the autoclaves - CEP.

4. Calcination: • Complete burning of the wax residue in a gas-heated chamber with an

oxidizing atmosphere;

• Supervisory system of the temperatures in the different passing zone of

the continuous furnace – CEP.


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5. Metal fusion and filling of the mold by CGP process:

• Filling of the mold with liquid metal upon the use of aspiration or counter

gravity process – CGP that enables the use of liquid metal temperatures lower than those

used in the conventional process (by gravity);

• Less oxidation of the liquid metal with less formation of slag and gases;

• Aspiration of the liquid metal below the slag line;

• Acquisition of walls of extra fine width in the invested casted, as well as

the most perfect and complete reproduction of the geometrical details.

6. Support to develop the manufacturing process:

• Internal availability of the essay with magnetic particles to detect

superficial discontinuities – Magnaflux;

• Internal availability of X-Ray essay to assess the inner sanity;

• Availability of a update and complete chemical-metallurgical lab.

7. Support to the Client’s Product Engineering (CO-DESIGN) • Proposition of sophisticated and economically feasible alternatives

providing greater agility on the interface between Engineering.


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TABLE 1

Chemical composition of the Investment Casted Alloys


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1. Carbon low-alloyed steels:

Alloy: %C %Mn %Si %Ni %Cr %Mo %P max.

%S max.

IC 1010 0.05-0.15

0.30-0.60

0.40-0.80

- - - 0.04 0.04

IC 1020 0.15-0.25

0.20-0.60

0.20-0.60

- - - 0.040 0.045

IC 1030 0.25-0.35

0.70-1.00

0.20-0.60

- - - 0.040 0.045

IC 1040 0.35-0.45

0.70-1.00

0.20-1.00

- - - 0.040 0.045

IC 1045 0.40-0.50

0.70-1.00

0.20-1.00

- - - 0.040 0.045

IC 1050 0.45-0.55

0.70-1.00

0.20-1.00

- - - 0.040 0.045

IC 1060 0.55-0.65

0.60-0.90

0.20-1.00

- - - 0.040 0.045

IC 1090 0.85-0.95

0.60-0.90

0.20-1.00

- - - 0.040 0.045

IC 3120 0.15-0.25

0.60-0.80

0.20-0.80

1.10-1.40

0.55-0.75

- 0.040 0.040

IC 4130 0.25-0.35

0.40-0.70

0.20-0.80

- 0.80-1.10

0.15-0.20

0.040 0.040

IC 4140 0.35-0.45

0.70-1.00

0.20-0.80

- 0.80-1.10

0.15-0.25

0.040 0.040

IC 4150 0.45-0.55

0.75-1.00

0.20-0.80

- 0.80-1.10

0.15-0.25

0.040 0.040

IC 4330 0.28-0.36

0.60-1.00

0.20-0.80

1.65-2.00

0.65-1.00

0.30-0.45

0.040 0.040

IC 4340 0.36-0.44

0.60-0.90

0.20-0.80

1.65-2.00

0.70-0.90

0.20-0.30

0.025 0.025

IC 4620 0.15-0.25

0.40-0.70

0.20-0.80

1.65-2.00

- 0.70-1.00

0.040 0.045

IC 6120 0.15-0.25

0.70-0.90

0.20-0.80

- 0.70-1.00

- 0.040 0.040

IC 6150 0.45-0.55

0.65-0.95

0.20-0.80

- 0.80-1.10

- 0.040 0.045

IC 8620 0.15-0.25

0.65-0.95

0.20-0.80

0.40-0.70

0.40-0.70

0.15-0.25

0.040 0.045

IC 8630 0.25-0.35

0.65-0.95

0.20-0.80

0.40-0.70

0.40-0.70

0.15-0.25

0.040 0.045

IC 8640 0.35-0.45

0.70-1.05

0.20-0.80

0.40-0.70

0.40-0.60

0.15-0.25

0.040 0.040

IC 8665 0.60-0.70

0.70-1.05

0.20-0.80

0.40-0.70

0.40-0.60

0.15-0.25

0.040 0.040

IC 8730 0.25-0.35

0.70-0.90

0.20-0.80

0.40-0.70

0.40-0.60

0.15-0.30

0.040 0.040

IC 8740 0.35-0.45

0.75-1.00

0.20-0.80

0.40-0.70

0.40-0.60

0.20-0.30

0.040 0.040

IC52100 0.95- 0.25- 0.20- - 1.30- - 0.040 0.045


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1.10 0.55 0.80 1.60

2. Tooling steels (*)

Alloy: %C %Mn %Si %Cr %Mo %W %V Others CA-2 0.95-

1.05 0.75 max.

1.50 max.

4.75- 5.50

0.90-1.40

- 0.20-0.50

CA-6 0.65-0.75

1.80-2.20

1.00 max.

0.80-1.20

0.80-1.30

- -

CD-2 1.4-1.6 1.00 max.

1.50 max

11.00- 13.00

0.70- 1.20

- 0.40- 1.00

CD-3 2.10-2.30

0.75 max.

1.00 max.

11.50-13.0

0.40 max.

- -

CD-6 2.10- 2.35

0.75 max.

0.80- 1.20

11.50- 13.00

0.40 max.

0.80- 1.20

-

CD-7 2.15- 2.45

0.75 max.

1.00 max.

11.50- 13.00

0.80- 1.20

- 3.50- 4.50

CH-11 0.30- 0.40

0.75 max.

0.95- 1.15

4.60- 5.40

1.20- 1.60

- 0.30- 0.50

CH-12 0.30- 0.40

0.75 max.

1.50 max.

4.75- 5.75

1.25- 1.75

1.00- 1.70

0.20- 0.50

CH-13 0.30- 0.42

0.75 max.

1.50 max.

4.75- 5.75

1.25- 1.75

- 0.75- 1.20

CM-2 0.78- 0.88

0.75 max.

1.00 max.

3.75- 4.50

4.50- 5.50

5.50- 6.75

1.25- 2.20

0.25 Ni

CM-4 1.25- 1.35

0.75 max.

1.00 max.

3.75- 4.50

4.50- 5.50

5.20- 6.20

3.60- 4.40

CO-1 0.85- 1.00

1.00-3.00

1.50 max

0.40- 1.00

- 0.40- 0.60

0.30 max.

CO-2 0.85- 0.95

1.50- 1.80

1.00 max.

0.40 max

0.30 max

- 0.30 max

CO-7 1.10- 1.20

0.75 max.

1.00 max.

0.50- 0.70

- 1.65- 1.85

0.15- 0.24

CS-1 0.45- 0.55

0.75 max.

1.00 max.

1.35- 1.65

- 2.35- 2.65

-

CS-2 0.45- 0.55

0.75 max

0.90- 1.20

- 0.40- 0.60

- 0.30 max

CS-5 0.50- 0.65

0.60- 1.00

1.75- 2.25

0.35 max

0.20- 0.80

- 0.35 max

CS-7 0.50- 0.60

0.50- 0.80

1.00 max.

3.00- 3.50

1.20- 1.60

- -

CT-1 0.65- 0.75

0.75 max.

1.00 max.

3.75- 4.50

- 17.75- 18.25

0.90- 1.30

CT-2 0.80- 0.90

0.75 max.

1.00 max.

3.75- 4.50

1.00 max

17.50- 19.00

1.80- 2.40

CT-6 0.75- 0.85

0.75 max

1.00 max.

4.00- 4.75

0.70- 1.00

18.50- 21.25

1.50- 2.10

(*) The content of P and S must not exceed 0.025% for each element, unless when agreed otherwise.


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3. Stainless Steel: Ferritic, Martensitic and Hardened by precipitation

Alloy: %C %Mn %Si %P max.

%S %Ni %Cr %Mo Cu Others

CA-15 (410)

0.05-0.15

1.00 max

1.50 max

0.040 0.04 max

1.00 max

11.50-14.00

0.50 max

-

IC-416

(416)

0.15 max.

1.25 max

1.50 max

0.050 0.15-0,35

0.50 max

11.50-14.00

0.50 max

0.50 max

0.10-0.30Se

instead of S and 0,5 Zr max.

CA-40 (420)

0.20- 0.40

1.00 max

1.50 max

0.040 0.040 1.00 max

11.50-14.00

0.50 max

-

IC 431 (431)

0.08- 0.15

1.00 max

1.00 max

0.040 0.040 1.50- 2.20

15.00-17.00

- - N: 0.03-0.12

C+N: 0.22 max

IC 440A

(440A)

0.60- 0.75

1.00 max

1.00 max

0.040 0.030 - 16.00-18.00

0.75 max

-

IC 440C

(440C)

0.95- 1.20

1.00 max

1.00 max

0.040 0.15- 0.35

0.75 max

16.00-18.00

0.35- 0.75

-

IC 440F

(440F)

0.95- 1.20

1.00 max

1.00 max

0.040 0.045 0.50 max

16.00-18.00

0.75 max

0.50 max

0,10-0,30Se

instead of S

IC 17-4 PH (17-4 PH)

0.060 max

0.70 max

0.50- 1.00

0.040 0.030 3.60- 4.60

15.50-16.70

- 2.80-3.50

Nb+Ta: 0.15-0.40 , N:0.05


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4. Austenitic Stainless Steels

Alloy: %C %Mn %Si %P max.

%S %Ni %Cr %Mo Cu Others

CF-20 (302)

0.20 max

1.50 max

2.00 max

0.040 0.040 8.00- 11.00

18.00-21.00

- -

CF-16F (303)

0.16 max

1.50 max

2.00 max

0.040 (*) 9.00- 12.00

18.00-21.00

0.40-0.80

- (*) or 0.2-0.35 Se or

0.20-0.40 S CF-8 (304)

0.08 max

1.50 max

2.00 max

0.040 0.040 8.00- 11.00

18.00-21.00

- -

CF-3 (304L)

0.03 max

1.50 max

2.00 max

0.040 0.040 8.00- 12.00

17.00 21.00

- -

CK-20 (310)

0.20 max

2.00 max

2.00 max

0.040 0.040 19.00- 22.00

23.00-27.00

- -

CF-8M (316)

0.08 max

1.50 max

2.00 max

0.040 0.040 9.00- 12.00

18.00- 21.00

2.00-3.00

-

IC 316-F 0.08 max

1.50 max

2.00 max

0.040 0.040 9.00-12.0

18.00- 21.00

2.00- 3.00

- (*) or 0.2-0.35 Se or

0.20-0.40 S

IC 321 (321)

0.08 max

2.00 max

1.00 max

0.040 0.030 9.00-12.0

17.00- 19.00

- Ti min.:

5 x %C CF-8C (347)

0.08 max

1.50 max

2.00 max

0.040 0.040 9.00- 12.00

18.00- 21.00

- - Nb: 8 x %C – 1,00

CN-7M 0.07 max

1.50 max

1.50 max

0.040 0.040 27.5- 30.5

19.00- 22.00

2.00-3.00

3.00- 4.00

HK 0.20-0.60

2.00 max

2.00 max

0.040 0.040 18.00- 22.00

24.00- 28.00

0.50 max

-

Note: Maximum 1% of total residual elements.


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TABLE 2

Mechanical Properties


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1. Carbon and Low-Alloyed Steels

Alloy: Condition Resistance Limit

Kg/mm2

Pouring Limit

Kg/mm2

Stretching % Hardness (range of

maximum) IC 1010 Annealed 35 - 42 21 - 25 30- 35 55 Rb IC 1020 Annealed 42 - 49 28 - 32 25 - 35 75 Rb

Annealed 45 - 53 32 - 35 20 - 30 75 Rb IC 1030 Tempered 60 - 105 42 - 105 0 - 15 20 – 50 Rc Annealed 56 - 63 35 - 42 20 - 25 100 Rb IC 1045 Tempered 70 - 126 63 - 126 0 - 10 25 – 57 Rc Annealed 63 - 77 35 - 45 20 - 25 100 Rb IC 1050 Tempered 87 - 126 70 - 126 0 - 10 30 – 60 Rc Annealed 70 - 84 38 - 49 12 - 20 25 Rc IC 1060 Tempered 84 - 140 70 - 126 0 - 5 30 – 60 Rc Annealed 77 - 105 49 - 56 5 -10 30 Rc IC 1090 Tempered 91 - 126 91 - 126 0 - 3 37 – 50 Rc Annealed - - - 100 Rb IC 3120 Tempered - - - - Annealed - - - 100 Rb IC 4130 Tempered 91 - 119 70 - 91 5 - 20 23 – 49 Rc Annealed - - - 100 Rb IC 4140 Tempered 91 - 140 70 - 108 5 -20 29 – 57 Rc Annealed - - - 100 Rb IC 4150 Tempered 98 - 140 84 - 126 5 - 10 25 – 58 Rc Annealed - - - 20 Rc IC 4330 Tempered 91 - 133 70 - 122 5 - 20 25 – 48 Rc Annealed - - - 20 Rc IC 4340 Tempered 91 - 140 70 - 126 5 - 20 20 -55 Rc Annealed - - - 100 Rb IC 4620 Tempered 77 - 105 63 - 91 10 - 20 20 – 32 Rc Annealed - - - 100 Rb IC 6120 Tempered - - - - Annealed - - - 100 Rb IC 6150 Tempered 98 - 140 84 - 126 5 - 10 30 – 60 Rc Annealed - - - 100 Rb IC 8620 Tempered 70 - 91 56 - 77 10 - 20 20 – 45 Rc Annealed - - - 100 Rb IC 8630 Tempered 84 - 119 70 - 91 7 - 20 25 – 50 Rc Annealed - - - 20 Rc IC 8640 Tempered 91 - 140 70 - 126 5 - 20 30 – 60 Rc Annealed - - - 25 Rc IC 8665 Tempered 119 - 154 98 - 140 0 - 10 - Annealed - - - 100 Rb IC 8730 Tempered 84 - 119 77 - 105 7 - 20 - Annealed - - - 100 Rb IC 8740 Tempered 98 - 140 84 - 126 5 - 10 30 – 60 Rc Annealed - - - 25 Rc IC

52100 Tempered 126 - 161 98 - 126 1 - 7 30 – 65 Rc


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2. Stainless Steel: Ferríitic, Martensitic and Hardened by precipitation

3. Austenitic Stainless Steel


Kg/mm2

Pouring Limit

Kg/mm2

Stretching %

Hardness (range or

maximum) Annealed - - - 100 Rb CA-15 (410) Tempered 67 - 140 52 - 112 5 - 12 94 Rb - 45 Rc Annealed - - - 100 Rb IC-416 (416) Tempered 67 - 140 52 - 112 3 - 8 94 Rb - 45 Rc Annealed - - - 25 Rc CA-40 (420) Tempered 140 - 157 90- 145 0 - 5 30 – 52 Rc Annealed - - - 30 Rc IC 431 (431) Tempered 77 - 112 52 - 73 5 - 20 20 – 40 Rc Annealed - - - 30 Rc IC 440A

(440A) Tempered - - - 35 – 56 Rc Annealed - - - 35 Rc IC 440C

(440C) Tempered - - - 40 – 60 Rc Annealed - - - 35 Rc IC 440F

(440F) Tempered - - - 40 – 60 Rc Annealed - - - 36 Rc IC 17-4 PH

(17-4 PH) Tempered 105 - 132 98 - 112 6 - 20 34 – 44 Rc


Kg/mm2

Pouring Limit

Kg/mm2

Stretching %

Hardness (range or

maximum) CF-20 (302) Solubilized 45 - 52 21 – 24 35 - 60 90 Rb

CF-16F (303) Solubilized 45 - 52 21 – 24 35 - 45 90 Rb CF-8 (304) Solubilized 49 - 59 28 - 35 30 – 50 90 Rb

CF-3 (304L) Solubilized 49 - 59 28 - 35 35 – 50 90 Rb CK-20 (310) Solubilized 42 - 52 21 - 28 35 – 45 90 Rb CF-8M (316) Solubilized 49 - 59 28 - 35 35 - 50 90 Rb

IC 316-F Solubilized 49 - 59 28 - 35 35 - 50 90 Rb IC 321 (321) Solubilized 45 - 52 21 - 28 35 -45 90 Rb CF-8C (347) Solubilized 49 - 59 22 - 25 30 – 40 90 Rb

CN-7M Solubilized 45 - 52 18 - 24 35 – 45 90 Rb HK Solubilized 45 - 52 24 - 31 10 - 20 100 Rb


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ATTACHMENT

VDG – P690 (MARCH 1999)*

DIMENSIONAL TOLERANCES, SURFACE STATES AND

ADDITIONAL TO THE MACHINING


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*free translation

1. Definition and validity range 1.1 Investment casted is a process by which casted parts of superficial quality

are manufactured by primary casting. Models produced through shaping by injection will be melted after manufacturing ceramic molds. The ceramic molds are destroyed after the casting. Due to this, t is mentioned the word “lost" both in models and in the molds. In most cases, the casting is performed by the use of hot molds.

1.2 – Iron, aluminum, nickel, cobalt, titanium, cupper, and magnesium-based

metals and alloys will be casted in lost wax. According to the type of the alloy, it will be casted in the air, under a protection gas or vacuum.

1.3 – The instruction booklet is not valid for noble metals, for items of the

jewelry industry and for dental prosthesis laboratories, which will be casted according to the wax melting processes, and neither for plastic casting.

2. Purpose 2.1- This instruction booklet defines the dimensional tolerances, mentions the

additional to the machining and the superficial roughness corresponding to the status of the lost wax casting technique. It serves as basis for a better economic cooperation between casting producers in lost wax and buyers of the casting in lost wax.

2.2- The technical data mentioned here are related to blasted surfaces treated

for protection, and treatment in chemical bath in the supplying state. The exceptions must be agreed when it is working processes that change dimensional tolerances.

2.3- When nothing different was agreed, the initial samples will be supplied in

the first order. They serve for the direct understanding of both parts. The buyer must check the initial samples. After checking, the casting must be informed in writing when releasing the serial manufacturing. Those deviations that will be accepted with the releasing or diagnosis on the quality of the initial sample must be mandatorily assumed in the drawing (of the casted parts) for the manufacturing.


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3. Dimensional precision 3.1 – Decreasing and shrinkage By the nature law, there are volumetric contractions through the decreasing and

shrinkage in the hardening and cooling of casted metals. Other influences in the production of the lost wax casting also result from the

decreasing of the lost models and by the expansion of the casting models to be heated. When manufacturing the injection molds, the sum of those influences will be observed respectively in the dimensions of such decreasing.

Those are experimental values, which depend on the contour of the casted part,

of the ceramic mold and the casted material, but also on the special manufacturing techniques of the individual sequences in lost wax.

3.2 Reference plans and points (please refer DIN - Book 7 of Rules) For investment casted parts, it is required that the drawings are systematically

dimensioned with reference plans and points (Figure 1) for the subsequent dimensional controlling and processing to match. Those reference plans and points must be previously defined by the constructor together with the lost wax caster. The zero position of the reference plans will be defined with accuracy by the dimensions of the reference points.

Figure 1. Reference plan ! reference points

The primary reference plan “A” will be fixed by three points A1, A2, and A3. It

must correspond to the large surface of the casted part, according to Figure 2. The secondary reference plan "B" has two reference points 81 and 82, which

must be disposed as far as possible over the longitudinal axis, as shown in Figure 2. The tertiary reference plan “C” has only one reference point C1, which should

be located in the middle of the casted part or around it, according to Figure 2.


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Figure 2.

The reference plans are placed through the axis of symmetry of the casted part.

Every reference point is disposed as to the subsequent processing cannot be remove or modified. The reference points must be located on the outer surfaces of the casted part. They can also be developed as elevated or deepened surfaces.

High reference points are beneficial in some casted parts with shape tolerances

and limited position. When determining the reference points, it must be observed that those positions shall not rest in a pouring area of de Casted.

This way, in difficult shapes, the casted part can be placed exactly at the

admission point by machining (previous). 3.3 Shape and extraction inclinations Usually, shape and extraction inclinations are not necessary. Exceptions

originated due to shape and casting technical requirements must be agreed between the supplier of the casted in lost wax and the buyer.


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4. Dimensional Tolerances 4.1 Linear dimensional tolerances Achievable dimensional tolerances in casted parts depend on the following

factors: - Material casted - Dimensions and shape of the casted part.

4.1.1 Material casted

The distribution of the tolerance fields of different features of the materials has influence on the manufacturing. Due to this, it is also valid the following series of tolerances contained in Table 1 for the different groups of materials:

Group of material D: Iron, nickel, cobalt and cupper-based alloys –D1 to D3 Degree of Precision.

4.1.2 Validity of the degree of precision Degree of precision 1 holds for every free dimension. Degree of precision 2 holds for the tolerated dimensions. Degree of precision 3 can only be kept in individual dimensions, and it must be

calculated with the lost wax caster, once it requires complementary manufacturing steps, as well as expensive tooling corrections.

Table 1. Linear tolerances

D1 D2 D3 D4 (Fupresa) Range of nominal dimension (mm) Field Field Field Field

Up to 6 0.30 0.24 0.20 0.14 From 6 to 10 0.36 0.25 0.22 0.16 From 10 to 18 0.44 0.34 0.28 0.20 From 18 to 30 0.52 0.40 0.34 0.24 From 30 to 50 0.80 0.62 0.50 0.35 From 50 to 80 0.90 0.74 0.60 0.42 From 80 to 120 1.10 0.88 0.70 0.49 From 120 to 180 1.50 1.30 1.0 0.70 From 180 to 250 2.40 1.90 1.5 1.05 From 250 to 315 2.60 2.20 1.6 -


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4.1.3 Position of the tolerance field The position of the tolerance field in relation to the nominal dimension is free of

choice. It is beneficial to place the tolerance field around the nominal dimension. On surfaces that must be machined, it must be observed the sum or difference of the tolerance field and the machining additional (see item 6).

4.2 Tolerances of shape and position The tolerances of shape and position restrict deviations in the molded element

of its - Shape - Direction, or - Place

Theoretically accurate regardless the effective dimension of the molded element.

The tolerances of shape and position assume that the reference plans and points (item 3.2) are defined with the assistance of the DIN ISO 1101 rule.

If the tolerances of shape and position are defined in the order, they must be

individually indicated, according to the Tables 2a – d.


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Table 2a. Tolerances of shape and position

Rightness, linear shape D1 D2 D3 Range of nominal

dimension (mm) Field Field Field Up to 6 0.15 0.12 0.10 From 6 to 10 0.18 0.14 0.12 From 10 to 18 0.25 0.20 0.15 From 18 to 30 0.30 0.25 0.20 From 30 to 50 0.40 0.35 0.25 From 50 to 80 0.60 0.45 0.30 From 80 to 120 0.80 0.60 0.45 From 120 to 180 1.10 0.80 0.60 From 180 to 250 1.50 1.15 0.90 From 250 to 315 1.90 1.40 1.20 From 315 to 400 2.40 1.80 1.50 From 400 to 500 3.00 2.20 1.80

Table 2b. Tolerances of shape and position: Flatness, superficial shape, circularity D1 D2 D3 Range of nominal


Table 2c. Tolerances of shape and position - Parallelism, Symmetry

D1 D2 D3 Range of nominal dimension (mm) Field Field Field Up to 6 0.25 0.20 0.15 From 6 to 10 0.30 0.25 0.20 From 10 to 18 0.40 0.30 0.25 From 18 to 30 0.50 0.40 0.30 From 30 to 50 0.70 0.60 0.50 From 50 to 80 1.00 0.80 0.65 From 80 to 120 1.30 1.10 0.90 From 120 to 180 1.80 1.50 1.20 From 180 to 250 2.50 2.00 1.60 From 250 to 315 3.15 2.60 2.00 From 315 to 400 3.80 3.20 2.50


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From 400 to 500 4.40 3.80 3.20

Table 2d. Tolerances of shape and position - Coaxiality, Cylindricity D1 D2 D3 Range of nominal


There are three degrees of precision available. An increase in the

manufacturing expense is associated with the increase in the degree of precision. The degree of precision 3 can only be observed in individual dimensions, and it must be agreed with the lost wax caster, as it requires additional manufacturing steps, as well as expensive tooling corrections.

Tolerances of shape and position whether diverging or not contained in Tables

2 a-d must be agreed between the buyer and the lost wax caster, and duly recorded in the drawing according to the DIN ISO 1101 rule.

4.3 Tolerances of Angle

Table 3: Tolerances of Angle Precision

1 2 3 Admissible direction deviation

Range of nominal dimension (1)

Angle minute

mm each 100 mm

Angle minute

mm each 100 mm

Angle minute

mm each 100 mm

Up to 30 mm 30 (2) .,87 30 (2) 0.87 20 (2) 0.58 From 30mm to 100mm

30 (2) 0.87 20 (2) 0.58 15 (2) 0.44

From 100mm to 200mm

30 (2) 0.87 15 (2) 0.44 10 (2) 0.29

Over 200mm 20 (2) 0.87 15 (2) 0.44 10 (2) 0.29 (1) Length of the smaller side is standard for a range of nominal dimension. (2) Angle can deviate in both directions.


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Tolerances of angle others than those shown in Table 3 must be agreed with the lost wax caster and recorded in the drawing according to the DIN ISO 1101 rule.

4.4 Radius of Curvature

Degree of Precision Range of nominal dimension (1) 1 2 3 Up to 5 mm ± 0.30 ± 0.20 ± 0.15 From 5mm to 10mm ± 0.45 ± 0.35 ± 0.25 From 10mm to 120mm ± 0.70 ± 0.50 ± 0.40 Over 120mm Linear (vide table 1)

Radius of curvature others than those shown in Table 4 must be agreed with

the lost wax caster. 4.5 Dimensional tolerances for the wall thickness The tolerances for the wall thickness depend on the following:

- Size of the casting mold walls reproduced (ceramic wall). - Interrupted surfaces - Possible thermal distortions - Isostatic compression of the fluid metal.

Due to this, the tolerances of the wall thickness do not depend on the degree of

precision. They are limited (or decreased) by the sections of the edges, interruptions (openings, holes), bars, flaps and similar casted together through which the wall thickness is “demanded".

The respective range of tolerance in question must be attained from Table 5. It

contains the standard tolerance of the wall thickness for the smaller side length of a surface per group of material.

Figure 3. Wall thickness

Case A: the surface formed by dimensions a and b is not interrupted.

Dimension b is smaller than dimension. A; dimension b sets the tolerance of the wall thickness, according to Figure 3.

Case B: the surface formed by dimensions a and b is interrupted by a central

hole. The non-interrupted surface will be then formed by dimensions b and c. Dimension c


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is smaller than dimension b. Dimension c sets the tolerance of the wall thickness as forecasted, according to Figure 3.

Table 5. Tolerances of the wall thickness Shorter side length of a surface (Figure 3) (mm)

Tolerance of thickness – Fe Alloys

Up to 50 ± 0.25 From 50 to 100 ± 0.30 From 100 to 180 ± 0.40 From 180 to 315 ± 0.50 Over 315 ± 0.60

4.6 Dimensional tolerances of pre-manufactured parts to be casted

together This must be agreed with the lost wax caster.

5. Superficial Quality Ra or Rz (CLA) according to Table 5 must be used for casted surfaces.

Table 6. Surface Roughness Normal surfaces CLA (µinches) Ra (µm) Rz (µm)

N7 63 1,6 8 N8 125 3,2 12 N9 250 6,3 25

Ranges N 7, N 8 and special surface treatments must be especially agreed and

recorded in the drawings according to the DIN ISO 1302 rule. When nothing different was agreed, the blasted N9 version is valid for the

supplying condition.

6. Additional for machining The dimensions of adjustment of the surfaces or smaller superficial rugosities

impossible to be attained through the lost wax casting have additional for the machining. The additional dimension must consider the specific features of the material and the not favorable position calculated within the tolerance range, including tolerances of shape and position.


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7. Complementary indications and data 7.1 Inner radii The radii in the inner corners (cavities) prevent casting failures and decrease

tension concentrations of the casted part to be used. The minimum radius must have approximately 20% of the larger thickness of

the wall thickness, however not lesser than 0.5mm. The amount desired is an inner radius corresponding at least to the lower wall thickness.

7.2 Outer radii and chamfer Lost wax casted parts do not have sharp edges with R=0. Due to this, the outer

radii and chamfer must be always indicated as maximum radii, for instance R<0.5 max. 7.3 Holes, blind holes, channels, grooves, and cracks In order to enable to cast in an advantageous way mounting holes, blind holes,

channels, grooves, and cracks, that is, without being allowed to cast together pre-molded ceramic nucleus, the values mentioned in tables 6 and 7 must be considered.

Table 7. Dimensions for the holes, blind holes, and channels

Greater length or depth Diameter or between other d (mm) Mounting (l) Blind (t)

2 to 4 ~ 1 x d ~ 0,6 x d 4 to 6 ~ 2 x d ~ 1,0 x d

6 to 10 ~ 3 x d ~ 1,6 x d Over 10 ~ 4 x d ~ 2,0 x d

Table 8. Dimensions for the grooves and cracks Greater depth below Width b (mm)

open (l) closed (t) 2 to 4 ~ 1 x b ~ 1,0 x b 4 to 6 ~ 2 x b ~ 1,0 x b

6 to 10 ~ 3 x b ~ 1,6 x b Over 10 ~ 4 x b ~ 2,0 x b

7.4 Identification of the casted parts If the casted parts will be identified, the size of the letters (following the DIN

1451 rule "mean") and location in the casted part must be agreed. The instruction VDG P 701 "Identification of casted parts" must be analogically used. The identifications can be embossed casted or in depth, preferably embossed on a deep background. The type and the identification mode from the supplier will be defined, whenever there is no specification in the drawing for such intent.


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8. Complementary information The complete process is presented in details in the booklet "lost wax casting for

industrial fields" from the technical series "construction + casting” of the Central to use the casting (Zentrale für Gussverwendung ZGV), Düsseldorf. It contains concrete indications on the materials, construction and several examples to provide high profitability in the lost wax casting.

Brochures from companies and booklets of materials for German lost wax

casting in the VDG inform on the respective line of products manufactured by each of them in lost wax casting.

This Project Manual was prepared by the Fupresa S/A Engineering Department

and revised/updated whenever appropriate.

FUPRESA S/A Project Manual 5th Edition - Aug / 2016

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Transcript of FUPRESA S/A Project Manual 5th Edition - Aug / 2016