The Foundrys Source for Preformed and Extruded Ceramic Cores

1

• The Foundrys Source for Preformed and Extruded
  Ceramic Cores

38240 Airport Parkway, Willoughby, Ohio
44094 440.946.6964 Fax [phone]
www.daiceramics.com
2
DAI Ceramics, Inc38240 Airport
ParkwayWilloughby, OH 44094
3
Introduction

• Molded Ceramic Cores
• Serving the foundry industry as well as other
  industries, DAI precision preformed ceramic cores
  are available in simple commercial shapes,
  complex airfoils and configurations for larger
  castings.
• Extruded Ceramic Cores
• DAI offers a wide range of extruded ceramic
  solutions.
• Solid or Hollow Extrusions
• Cross sections such as squares, rectangles,
  triangles, ovals, etc
• /- 0.001 is typically held on diameters up to a
  half inch and/- 0.002 can be held on anything
  larger
• Extrusions can be threaded to decrease machining
  operations after casting.
• The threading services available at DAI Ceramics
  insure that all threaded cores meet our
  customers special requirements.

4
Introduction

• X - Ray Capabilities
• DAI puts all product through precise inspection
  procedures at all phases of production in order
  to insure quality ceramic cores. Visual and
  dimensional inspections are conducted based on
  customer requirements and specifications. DAI
  works closely with each customer to create
  inspection criteria and specifications that meet
  customer requirements and DAI's capabilities.
• As part of the quality process DAI does have
  x-ray capabilities for ceramic core inspection.
• Materials
• Today's investment foundries use a wide variety
  of alloys. DAI offers ceramic core materials
  compatible with nearly all of these alloys
  including Air Cast, Directional Solidified and
  Single Crystal alloys.
• Uniform properties and consistent dimensions in
  ceramic cores are important in the investment
  casting process. DAI's materials, processes and
  controls guarantee the production of large
  numbers of cores with virtually identical
  properties.
• Controlled Sintering
• The firing process is one of several important
  steps in making a consistent ceramic core. Our
  controlled firing assures each batch of cores is
  fired to established parameters.

5
Ceramic cores are fired in electric batch kilns
at the required temperatures.
6
Core Body Characteristics

• Fused Silica
• Fused Silica and Zircon
• Cores are leached out of the casting through
  conventional means
• DAI has both low pressure and high pressure
  injection capabilities
• Smaller cores may be injected in high pressure or
  low pressure depending on size and geometry
• Larger (IGT) cores are done in the low pressure
  injection process
• Materials suitable for equiax and DS/Single
  Crystal castings

7
Shrink Factors

• Shrink factors will vary depending upon which mix
  is used. DAI offers several different mixes in
  both low pressure and high pressure processes.
• High pressure shrink factors are similar to
  shrink factors currently used in the industry.

8
Tooling

• High pressure injection requires steel tooling,
  D2, P20 or something similar.
• With our low pressure process we can use aluminum
  or steel tooling depending on the amount of
  detail.
• Ren or epoxy tooling can not be used.
• No setters or fixtures are required with DAIs
  firing process.

9
Injection Capabilities

• DAI has twelve high pressure injection machines
  ranging in size from 30 ton to 150 ton.
• DAI currently has one low pressure 150-ton
  ceramic injection machine.

Low Pressure Injection Machine
10
CMM Capabilities

• Sheffield CMM Machine
• Software PC DMIS

11
Additional Information

• DAI has three CNC machines used for finishing
  airfoil cores with slots and pedestals.
• DAI has a small core prep department that gives
  us the ability to ship cores ready for wax
  injection.
• DAI is Certified to ISO 90012000, with design.
• DAI is currently doing work with all of the major
  investment casting foundries.

CNC Operation
12
For More Information

• Call 440.946.6964
• Fax [phone]
• Email sales_at_daiceramics.com
• Website www.daiceramics.com