Modern engineering demands absolute reliability from cast components—especially in aerospace, defense, power generation and high-performance industrial equipment. At Investment & Precision Castings Ltd. (IPCL), we combine precision investment casting with Hot Isostatic Pressing (HIP) to deliver parts with exceptional structural integrity, uniform density and superior mechanical properties.
IPCL’s HIP System – Furnace & Capability
IPCL’s in-house HIP capability is built around a high-temperature, high-pressure Molybdenum furnace designed specifically for superalloy and high-alloy steel castings.
- Furnace: 1450°C Molybdenum furnace
- Working Pressure: 29,000 PSI (200 MPa ≈ 2000 Bar)
- Hot Zone: 300 mm × 400 mm
- Atmosphere: High-purity Argon gas
These parameters allow us to densify complex Nickel-, Cobalt- and steel castings to near-100% density, with excellent repeatability.
How HIP Enhances Investment Castings
Even with optimized gating and process control, castings can retain microscopic shrinkage cavities or isolated pores. HIP addresses these issues at the microstructural level.
| Benefit | Without HIP | With HIP |
|---|---|---|
| Internal Porosity | Localized shrinkage and micro-voids may remain | Collapsed and healed, near-fully dense structure |
| Fatigue Strength | Limited by internal defects | Significantly improved fatigue life |
| Creep & High-Temperature Performance | Baseline for alloy capability | Better resistance to long-term deformation and rupture |
| Pressure-Tightness | Potential leak paths via pores | Improved leak-tight performance |
| Machinability | Property variations across sections | More uniform response and reduced tool wear |
HIP + Casting: A Powerful Combination at IPCL
HIP does not replace good casting practice—it amplifies it. IPCL’s process chain is designed so that investment casting establishes precise shape and geometry, while HIP ensures internal integrity and longevity, especially for demanding projects.
| Capability | IPCL Investment Casting | After HIP | Result for Customer |
|---|---|---|---|
| Dimensional Accuracy | Near-net shape, tight tolerances | Geometry preserved | Aerospace-grade repeatability |
| Surface Finish | As-cast Ra as low as 1.6–3.2 µm (for vacuum cast parts) | Unchanged | Minimal machining and finishing |
| Internal Soundness | Very good with controlled process | Fully densified section | Confidence in critical sections and junctions |
| Mechanical Strength | High, alloy-dependent | Enhanced ultimate and fatigue strength | Longer life in service |
| Reliability in Service | Good for standard duty | Exceptional for critical duty | Suited for aerospace, defense and high-risk applications |
Typical Applications of HIP-Enhanced Castings
By combining investment casting and HIP, IPCL supports customers in areas where failure is simply not acceptable:
- Aircraft engine turbine blades, vanes and hot-section hardware
- Combustor and nozzle components in gas turbines
- Rotors, impellers and high-speed rotating equipment
- High-pressure and high-temperature housings and manifolds
- Critical defense components and control hardware
- Energy-sector components exposed to extreme environments
Where HIP Fits in IPCL’s Manufacturing Flow
HIP is integrated into IPCL’s manufacturing route as a planned value-adding step. The flow below shows how casting, heat treatment and HIP work together to deliver fully verified components.
Wax Tooling & Pattern Assembly
Precision wax patterns are produced and assembled into clusters designed for optimal metal flow and feeding.
Ceramic Shell & Investment Casting
Multi-layer ceramic shells are built, dewaxed and poured to create near-net shape castings in Nickel, Cobalt and steel alloys.
Heat Treatment & HIP Densification
Alloys are heat treated, then processed in IPCL’s 1450°C, 29,000 PSI HIP system to eliminate internal porosity and stabilise microstructure.
Finishing & Final Inspection
Components are fettled, machined and validated by NDT (UT/RT/PT) and CMM inspection before shipment.
This combination of shape control, microstructural densification and rigorous verification ensures that IPCL components meet stringent global specifications from drawing to delivery.
Additional Casting Capabilities at IPCL
Along with Hot Isostatic Pressing (HIP), IPCL is also a leading provider of vacuum investment casting for Nickel- and Cobalt-base alloys. Our vacuum melting and pouring systems operate at ≤10⁻⁵ mbar, enabling oxide-free, high-integrity components for aerospace and high-temperature applications.
IPCL additionally offers aluminium investment castings, supporting lightweight, high-strength components for automotive, industrial, and energy applications. Aluminium castings produced through the lost-wax route offer superior dimensional precision, excellent machinability, and consistent quality for complex geometries.
These combined capabilities — vacuum casting, aluminium casting, and HIP densification — allow IPCL to serve a broad spectrum of industries with exceptional metallurgical quality and repeatable performance.