Capital Injection Ceramics Limited

Process

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Introduction

CIC has invested in the most up to date production, process control, measurement and testing equipment to ensure product quality and consistency.

CIC has proven its capability by successfully producing some of the largest and most complex blades and vanes for aerospace and IGT.

Injection Moulding

Ceramic cores are manufactured by medium pressure injection moulding. This gives an extremely dimensionally accurate and consistent product. CIC material shrinkage can be fine tuned to suit customers’ existing tools. CIC can offer a full tooling package and engineering support. The medium pressure process combined with CIC’s unique binder system results in very low tool wear rates – lifetimes of 50,000 to 100,000 for hardened steel tools are normal depending on geometry.

CIC has a range of press sizes suitable for cores ranging from a few grams to over 10 kg.

Dimensional Control

CIC’s core bodies are exceptionally stable and high tolerances can be maintained with minimal split lines, less dressing and flash. CIC’s process can produce features that are not achievable with other methods, examples include Trailing Edge thicknesses of 0.35 mm and an M5 thread profile that does not need machining.

For the most complex cores prone to distortion during firing, reforming techniques and/or core setter technology can be utilised.

Firing

CIC’s kiln firings are operated with sophisticated cycle controllers; firing cycles are monitored by chart recorders as well as Buller’s rings in every kiln load.

Finishing

Cores can be CNC finished on-site, giving benefits of accuracy, consistency and efficiency. The CNC machine incorporates a probe capable of finishing hte largest and most complex cores.

Strengthening

Cores can be strengthened if required with either urea or phenolic resin. Dependent on core geometry/cross section, strengths can typically be improved by a factor of 2 to 4 times.

Coating

Coatings can be applied to products, where suitable, to eliminate surface reaction with certain alloys.

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