Ceramic Shells

The Effect of Firing Times on Ceramic Shell Moulds - 5th World Conference Italy 1980

Over recent years the trend towards larger and heavier-sectioned investment castings has increased. This has brought its own problems, namely an increase in the incidence of deformed castings. The BICTA Refractories Committee’s Working Group under the Chairmanship of the author investigates the Hot Deformation of Ceramic Shell Moulds using a range of formulations comprised of fillers and stucco of fused silica, zircon and Molochite®, with silica sol and ethyl-silicate as bounding liquids.

An Alternative Back-up Filler to Zircon - 20th BICTA Conference UK 1989

The recent scarcity of zircon, the escalation of world prices and the general increase in demand has heightened the need to look for alternatives to zircon refractories as a raw material for investment casting shells. The author reviews requirements, cost and possible alternatives.

An Alternative Water Based Shell System for DS/SC Components - 21st BICTA Conference UK 1991

This paper seeks to compare and evaluate a new binder (Fascote) with traditional binder (silica sol) for fused alumina ceramic shell system for directional solidification (DS) and single crystal (SC) casting technology. Comparison test & trials were carried out on Centro Svilluppo Material (CSM, Italy) standard shell system using both new and traditional binders, with an emphasis on process drying times, high temperature properties and ceramic shell manufacturing cost.

Comparison of Fused Alumina Shell Systems for DS/SC Components - 22nd EICF Conference France 1992 & 40th ICI Conference USA 1992

The purpose of this paper is to evaluate traditional and rapid drying water-based binders using fused alumina for the manufacture of DS/SC components. The effect of environmental conditions (%RH & air flow rate) on the shell drying times and the comparison of hot strength tests (modulus of rupture & creep) for fused alumina ceramic shell systems are discussed.

The Effect of Using 75 & 45 Micron Grade Zircon DS/SC Shell Systems - 8th World Conference UK, 1993

This paper examines the effect of particle size distribution of zircon material on the hot mechanical properties of zircon/alumina shell systems for DS/SC. Experimental work was carried out on 75 and 45 micron grades of zircon material using a water based ceramic shell system. Dilatometry (DIL) tests were undertaken to analyse the phase changes during the sintering cycle of the various ceramic shell systems.

 An Insight into the Manufacture of Ceramic Shell Moulds – BICTA’s Shell Technology ‘Teach in’ 1984, 1988, 1994, 1999, 2000

An informative paper updated over the years to cover ceramic shell mould manufacture and the techniques and the equipment necessary for controlling the process.

Prevention of Ceramic of  Shell Defects – Sept. 2000, FTJ International

If foundries adopt a pro-active attitude towards the manufacture of sound cast components with an emphasis on prevention rather than cure then the possibility of manufacturing defective castings can be minimised.

Process  

Investment Casting – the Multi-process Technology – September 1988 FTJ International

In this wide-ranging review of the latest trend in investment casting, the author first traces the development of the process, before providing an insight into current practice. The presentation is divided into two main sections, one dealing with mould and core productions, the other with pouring techniques. Under the latter heading, reference is made to directionally-solidified and single-crystal casting processes. The article ends with a brief account of progress in the casting of titanium and hot isostatic pressing, and possible future development.

Robots at the Heart of the Investment Casting Industry – June 1989 FTJ International

The application of robots in the investment casting plant has opened up new horizons for the industry, not least being the ability to handle substantially heavier shell moulds, and the achievement of a ceramic shell consistency, mould-to-mould, difficult to obtain by manual procedures. The author provides advice in choosing and employing robots for the routine operations of dipping, draining and stuccoing wax assemblies in the application of both primary and secondary ceramic coats.

Automation in the Investment Casting Industry-from Wax Room to Finishing – March 1993, FTJ International

The author examines the latest trends in the application of automation for  the production of precision investment castings. The review is wide ranging, covering production of wax patterns, assembly, shell build-up, dewaxing and cleaning

Foundries

KanCast Components invest in the Future – June 1987 FTJ International

In a bid to further increase the efficiency of their Swedish-based foundry, KanCast Components AB have recently undergone a rationalisation project. The company, which specialises in investment castings, divides its operations into markets – aircraft and gas-turbine industries, and general industry. The following report describes the changes that have taken place and the capital investments required, to combine the two plants into a single operational process.

MMG-Hungary’s Premium Investment-Casting Foundry – July 1988, FTJ International

The author describes the manufacturing facilities employed by the Hungarian MMG organisation, leading producers of a wide range of investment castings. It is shown that such components are made in steel, copper-rich alloys, and light metals. The foundry is very well equipped, current resources including two Shell-O-Matic robot lines and a Leybold Heraeus melt furnace. Further modernisation, to the value of £250,000, is to be carried out in the next 12 months.

Italian CSM Organisation researches Advanced Investment Casting Technology – June 1992 FTJ International

The author provides an insight into research into advanced investment technology in the particular context of aeronautical gas turbines currently being carried out by the Italian organisation Centro Sviluppo Materiali (CSM). It is shown that work includes vacuum-cast equiaxed, directionally-solidified and single-crystal components.

From Wire to Investment Casting – Feb. 2001 Foundry Trade Journal

By using a specialist consultant (INCAST Consultancy), one Indian company has successfully adapted its manufacturing processes to accommodate a changing market.

Markets

Markets in South Asia - 23rd EICF Conference Czech Republic 1994, 23 BICTA Conference, UK 1997 

A short review of the market size and the number of investment casting foundries in South Asia, India, Pakistan and part of the Pacific Rim.

An Evaluation of UK Investment Casting in Year 2000

A general study of market size, value, tonnage, trend analysis & key players for the UK investment casting industry.

Seminars on the Investment Casting Process –Lecture Titles.

Wax Material

Properties, Specification & Testing for Wax Materials

Wax Injection Machines & Wax Pattern Manufacture

Wax Pattern Assembly

Introduction to Ceramic Shell Manufacturing

Binders & Refractory Filler Materials

Testing of Binders Slurries & Refractories Materials

Plant & Equipment in the Mould Room

Feeding & Gating of Investment Castings

Dewaxing & Firing of Ceramic Shell Moulds

Casting Processes

Post Casting Operations

Non-Destructive Testing & Final Inspection

Process Control

An Insight into the Manufacture of Ceramic Shell Moulds – BICTA’s Shell Technology ‘Teach in’ 1984, 1988, 1994, 1999, 2000

An informative paper updated over the years to cover ceramic shell mould manufacture and the techniques and the equipment necessary for controlling the process.

Patent No: EP0530658