Investment casting has been used to manufacture weapons, jewellery and
investment casting
during the ancient civilization. Today, its applications include jewellery/art
castings, turbine blades and many more industrial/scientific components. The present
paper reviews various investigations made by researchers in different stages of
investment casting and highlights their importance. The paper initially highlights the
investigations made on pattern wax properties, effects of blending, additives and
fillers. Different ways through which pattern properties (like surface finish,
dimensional accuracy, etc.) could be enhanced by properly controlling the injection
processing parameters are thoroughly discussed. The paper also looks into the
investigations made to enhance the strength, surface finish, etc. of ceramic shell for
ferrous alloys/non-ferrous alloys as well as superalloys in investment casting.
Investigations made on incorporation of nylon fibers and polymer additions confirm
that a ceramic shell reinforced with nylon fibers attains additional permeability
compared to the one with polymer additions.
Different investigations carried out on autoclave dewaxing and microwave dewaxing
conclude that the wax properties are less altered with microwave dewaxing when
compared to an autoclave dewaxing. Some recent investigations carried out on pouring
and post-treatment operations are also discussed in the paper. The advent and
emergence of rapid prototyping in shell mold casting are broadly exposed in the subsequent sections
of the paper. Various aspects of rapid prototyping like rapid investment casting,
rapid freeze prototyping, etc., along with their advantages are projected. The
emerging areas of applications of rapid prototyping like dentistry, etc., are duly
discussed.
The casting of titanium based alloys presents considerable problems, including the
extensive interactions that occur between the metal and refractory. In this work, CaO
stabilised zirconia was used as a primary coat material on the investment casting
mould. The reaction between the zirconia face-coat and a Ti-46Al-8Nb-1B alloy was
evaluated at three mould pre-heating temperatures: 500°C, 1000°C and 1200 °C. The
effect of casting dimensions on interaction was also included in this work and the
computer simulation of metal cooling profiles was carried out to assist the analysis.
Higher mould pre-heat temperature and larger casting dimensions enhanced the
interaction between the shell and the TiAl alloy associated with longer metal
solidification time. During the high temperature casting process, not only were O and
Zr observed penetrating into the metal from the decomposition of the face-coat
materials, but also Si which had penetrated from the backup coat was found to have
interacted with the metal.
Investment casting is competitive with all other casting processes where the size
of the product is within a mutually castable range. Though investment casting is used
to produce metal parts of any intricate shapes with excellent surface finish, it
suffers from long lead time and high tooling costs, which makes it uneconomical for
the production of either single casting, or small and medium production units. These
problems could be overcome by the applications of rapid prototyping and rapid tooling
technologies for low-volume investment casting production runs. The present article
analyzes different classifications of rapid prototyping techniques and it reviews
various investigations made on the usability of rapid prototyping- and rapid tooling-
integrated investment casting process, with their advantages and limitations. The
emerging areas of applications of rapid prototyping like dentistry, jewelry, surgical
implants, turbine blades, etc., are accordingly discussed. Further, an elaborate
discussion is made on the application of newer technologies for directly developing
ceramic shells. This article also emphasizes on various future scopes possible in
rapid prototyping-integrated investment casting process.
Investment casting
process is known to its capability of producing clear net shape, high-
dimensional accuracy and intricate design. Consistent research effort has been made by
various researchers with an objective to explore the world of investment casting.
Literature review revealed the effect of processing parameters on output parameters of
cast specimen. This article highlights the advancements made and proposed at each step
of investment casting and its hybridization with other process. Besides, investment
casting has always been known to manufacture parts such as weapons, jewellery item,
idols and statues of god and goddess since 3000 BC; this article reviews the present
applications and trends in combination of rapid prototyping technique as integrated
investment casting to serve in medical science. Advancements in shell moulding with
incorporation of fibre and polymer, development of alternative feedstock filament to
fused deposition modelling are duly discussed. The aim of this review article is to
present state of art review of investment casting since 3200 BC. This article is
organized as follows: in section ‘Introduction’, introduction to investment casting
steps is given along with researches undertaken at each step; in section ‘Rapid
prototyping technique’, background is given on the concept of rapid prototyping
technique by examining the various approaches taken in the literature for defining
rapid prototyping technique; section ‘Biomedical applications of RPT’ presents the
medicine or biomedical applications of investment casting and rapid prototyping
technique; section ‘Future trends’ provides some perspectives on future research and
section ‘Conclusion’ closes the article by offering conclusions.
In order to improve the properties of silicon sol shell for
shell mold casting
process, natural plant fibers combined with aluminum silicate fibers at
natural-to-aluminum silicate fibers mass ratio of 1:1 were mixed into the slurries
preparing for fiber-reinforced shell. The flexural strength of specimens of green
shells, fired shells at different temperatures and the self-loaded deformation of the
latter at elevated temperature were investigated. The fracture surface of shell
specimens was observed by SEM. The results show that the green strength of shell
specimens increases firstly and then decreases with variation of content of fiber from
0.2% to 1.0%. However, the self-loaded deformation at elevated temperature firstly
decreases and then increases. The green strength of shell specimens reinforced with
0.6% fibers reaches the maximum of 2.94 MPa. The bending strength of shell specimens
reinforced with 0.6% fibers fired at 900℃ reaches 4.04 MPa, approaching that of the
non-reinforced shell specimens. It is found by SEM that the failure of the fiber-
reinforced shell specimens at the applied load is resulted in breakdown of silicon sol
films and pulling-out, fracturing and debonding of fibers in the shell.
The development of manufacturing processes for high-performance investment casting
components in turbomachinery is an iterative process, which takes a lot of development
time for engineers and foundry occupation. The reduction of these expensive
preliminary tests is possible by combining probabilistic methods with modern
simulation tools for the numerical description of the
what is investment casting and solidification processes. Starting
from the deterministic simulation of the casting process, the casting and
solidification parameters including their production tolerances are taken into account
in the probabilistic simulation. Through a multi-dimensional statistical analysis of
the numerous parameters of the casting process and the achieved virtual casting
results, the correlations between the process parameters and component quality can be
worked out. Furthermore, a design of experiment (DoE) was performed with real castings
to confirm the influence of the main parameters on the result quantities. Mechanical
and microstructural characterizations of appropriate cast specimens allow a validation
of the simulation results and the formulation of casting parameter–microstructure–
property relations. The mechanical properties are studied by uniaxial hot tensile
tests using standard and small-scale specimens. Furthermore, the uniaxial fatigue
behavior and the life times at elevated temperatures are investigated.
In order to reduce the interaction between the Ti alloys and ceramic shell during
the casting, materials with high thermal and chemical inertness were used in
investment casting. An investigation was undertaken to analyze the influence of the
change of binder systems on the slurries, facecoats and the thermo-chemical properties
of the facecoat systems using an Y2O3–ZrO2 filler material. The results showed that,
using alumina-sol as the binder in the slurry gave the longest life of around three
days followed by that using the commercially available zirconia-sol at around 6 h, and
the yttria sol based slurry giving a shortest life of around 1.5 h. Meanwhile using
the alumina-sol can also enhance the facecoat sintering properties. There was no
obvious evidence observed that the change of the binder system influenced the facecoat
chemical inertness.
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