In 2005, the Microfusione Stellite SpA facility (a member of the Deloro Stellite Group) in Milan, Italy faced a big manufacturing challenge. During the production of fuel injector system components, a ceramic core was used to form the interior of the part. The injector is a complex component with small holes designed for fuel to pass through during the injection process. The ceramic core created the desired form, but after pouring the molten metal into the form, during the cooling process, the ceramic core left metallurgical defects in the injector, making them unusable.

 

Microfusione Stellite determined that a ceramic shell could be made by pouring the ceramic slurry directly on to the wax model, instead of using a pre-moulded ceramic core. This method required the use of a “window” in the mould, for the slurry to pass through to fill the interior portion of the injector. After the component cools and the ceramic is removed, the “window” is then welded shut.

 

This solutions not only solved the problem of metallurgical inclusions, but also eliminated the use of a ceramic core, saving development time and costs.