MPI has conducted a customer survey to determine what problems investment casting foundries are experiencing in their wax rooms. This paper provides the details of that survey. We have analyzed the results to determine, by industry served, what are the most common defects in the wax room. Tech Cast, LLC was one of the foundries that responded to our survey and agreed to allow testing on their equipment to evaluate the defects, conduct troubleshooting (optimization) and ultimately mitigate the defect. The corrective action(s) necessary to resolve the issues are explained as well as the outcome of making the needed process changes. Where applicable, the ICI Atlas of Wax Pattern Defects, as well as the ICI Process Control Course Materials are referenced. MPI's Wax-room Operator and Advanced Operator Training also served as a guideline for the appropriate optimization theory. It is our experience that the correct application of process controls and capable equipment addresses wax-room defects. High level control capabilities, combined with training on how to properly troubleshoot defects and a good understanding of how to modify current processes will mitigate or even eliminate the defects leading to increased productivity and decreased scrap.
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