Course detail

Precision Casting Technology

FSI-PSLAcad. year: 2026/2027

The course provides a comprehensive overview of Investment casting (IC) technology, with an emphasis on fundamental principles, materials, and manufacturing processes involved in the production of precision castings. Students are introduced to the entire technological chain, from wax pattern preparation and ceramic mold fabrication to melting, casting, and subsequent processing of castings. Special attention is given to the design and optimization of gating systems, the development and testing of ceramic slurries and shells, and the production of ceramic and wax cores. The course also covers advanced topics such as numerical simulation of IC processes, the application of 3D printing technologies, and the analysis of shell cracking phenomena. The practical component of the course includes methods for testing waxes, ceramic slurries, and shells, as well as non-destructive testing (NDT) of finished castings. Students also become familiar with modern trends in automation, robotics, and the use of artificial intelligence in industrial investment casting practice.

Language of instruction

Czech

Number of ECTS credits

5

Mode of study

Not applicable.

Guarantor

doc. Ing. Vladimír Krutiš, Ph.D.

Department

Institute of Manufacturing Technology (ÚST)

Entry knowledge

Basic knowledge of conventional methods of casting manufacture
and foundry alloys and their properties.

Rules for evaluation and completion of the course

Attendance in lectures is recommended; attendance in exercises is obligatory.
Credit for exercises: semester project 
Examination: written and oral exam.

Non-participation in an exercise can be compensated after consultation with the teacher.

Aims

The course aims to provide students with a comprehensive overview of investment casting technology, focusing on the fundamental principles, materials, and manufacturing processes involved in the production of precision castings. Students will become familiar with the entire technological chain, from wax pattern preparation and ceramic mold fabrication to melting, casting, and subsequent processing of castings. A key component of the course is mastering the design and optimization of gating systems, as well as the development and testing of ceramic slurries, shell materials, and the production of ceramic and wax cores. The course also covers advanced technologies, including numerical simulation of IC processes, the application of 3D printing technologies, and the analysis of shell cracking phenomena. The practical part of the course focuses on testing waxes, ceramic slurries, and shells, including non-destructive testing (NDT) of finished castings. Students will also become familiar with current trends in automation, robotics, and the use of artificial intelligence in industrial investment casting practice, enabling them to apply the acquired knowledge in real industrial environments.

Study aids

The materials will be accessible through e-learning.

Prerequisites and corequisites

Not applicable.

Basic literature

BEELEY, Peter R. a SMART, Robert F. Investment casting. Druhé vydání. Velká Británie: Maney Publishing, 2008. ISBN 9781906540579
CAMPBELL, John. Complete casting handbook: metal casting processes, metallurgy, techniques and design. 1st ed. Oxford: Butterworth-Heinemann, 2011. ISBN 978-1-85617-809-9.
KRUTIŠ, Vladimír; NOVOSAD, Pavel; ZÁDĚRA, Antonín a KAŇA, Václav. Requirements for Hybrid Technology Enabling the Production of High-Precision Thin-Wall Castings. online. Materials. 2022, roč. 15, č. 11. ISSN 1996-1944. Dostupné z: https://doi.org/10.3390/ma15113805. [cit. 2024-11-15].
STEFANESCU, Doru Michael. Science and engineering of casting solidification. 2nd ed. New York: Springer, 2009. ISBN 978-0-387-74609-8. (EN)
THOMAS-SADOWSKI, Susan. Basic principles of gating & risering. 2nd ed. Schaumburg, Ill.: American Foundry Society, c2008. ISBN 978-0-87433-315-2. (EN)

Recommended reading

Not applicable.

Classification of course in study plans

  • Programme N-SLE-P Master's 2 year of study, winter semester, compulsory

Type of course unit

 

Lecture

39 hod., optionally

Teacher / Lecturer

doc. Ing. Vladimír Krutiš, Ph.D.

Syllabus

  1. Introduction to Investment Casting Technology – Fundamentals of the Process
  2. Investment Casting (IC) – Advanced Technology for the Production of Thin-Walled Castings
  3. Comprehensive Overview of Wax Pattern Design and Manufacture
  4. Design of Gating Systems and Master Molds
  5. Wax Pattern Injection and Fabrication of Ceramic Cores
  6. Ceramic Slurries – Principles, Composition, and Development
  7. Ceramic Slurries – Emerging Trends and Applications of Engineered Slurry Systems
  8. Ceramic Stucco Materials and Application Techniques
  9. Dewaxing and Firing Processes for Wax Patterns
  10. Melting Equipment and Furnace Systems in Investment Casting Technology
  11. Automation and Robotics in Investment Casting Manufacturing
  12. Defects and Process Failures in Investment Casting Technology
  13. Managerial and Operational Perspectives on Investment Casting Foundries

Laboratory exercise

26 hod., compulsory

Teacher / Lecturer

doc. Ing. Vladimír Krutiš, Ph.D.

Syllabus

  1. Project / Semester Assignment Definition
  2. Numerical Simulation – Specific Aspects of Investment Casting (IC) Simulation
  3. Methods for Testing Wax Materials
  4. 3D Printing Technologies for Investment Casting – Shell Cracking Phenomena
  5. Production of Pressed Cores and Cast Core Manufacturing (SHAW Process) – Gelation Testing
  6. Methods for Testing Ceramic Slurries
  7. Testing of Ceramic Shells – Permeability and Strength Evaluation
  8. Ceramic Core Manufacturing – Industrial Excursion to LANIK Company
  9. Leaching Processes for Ceramic Cores
  10. Vacuum Furnace Melting – Industrial Excursion to PBS
  11. Artificial Intelligence in Industrial Practice
  12. Non-Destructive Testing (NDT) Methods
  13. Presentation of Semester Projects