These methods are mainly based on flat bar specimens and require specialized equipment to conduct the test. This paper will explore the development of a new and
novel approach to measuring shell properties and better understand shell cracking and more importantly, resistance to cracking. This method is intended to quantify a shell’s capability to resist internal pressure up and until fracture. Shell properties determined through this new method
can be evaluated initially against traditionally measured shell properties measurements. Once this test is validated, benchmarking studies will be made to compare the results from various shell systems and shell construction combinations. Keywords: Drying and Dewaxing Ceramic Shells
10:15 a.m. - 10:30 a.m. COFFEE BREAK
10:30 a.m. - 11:10 a.m. Paper No. 3 Transformative Solution for Investment Casters with Comprehensive Casting Solutions CrackAttack® Justin Neutra and Dylan Carpino, Hitchiner Manufacturing Co., Inc. Single crystal investment casting poses unique
challenges to shell systems. Extended time at temperatures close to the upper limit of the shell material’s capabilities, can result in mold distortion or outright failure. Dissimilar shell materials, temperature gradients, material decomposition and hydraulic pressure exerted by molten alloy can all have a significant impact on the performance of the shell. Processing single crystal molds may require the sealing of vents, reinforcement, or augmentation of the mold itself with a patching operation before casting. This patch material must be engineered to survive the challenging environment required for single crystal casting, be compatible with the shell system, and consider the need for reduced process time and labor whenever possible. A new, two component material has been invented
by Comprehensive Casting Solutions that addresses these challenges. This paper will discuss the use of this patch material which is offered as a two-part system composed of a proprietary ceramic flour and colloidal silica binder. This patch material allows rapid curing with good ‘green’ strength and the ability to insert dried shells quickly into furnaces for preheating and pouring. Hitchiner Manufacturing Company, Inc. has
implemented this new two component system in its counter gravity single crystal casting foundry and will present their thoughts on its performance. Keywords: Ceramics and Mold Making
11:10 a.m. - 11:50 a.m. Paper No. 4 Implementation of an Automated System for Slurry Viscosity and Density Measurement: Impact on Shell Quality and Labor Efficiency
July 2025 ❘ 19 ®
Caroline E. Giacomin, Sunil Kumar, Rheonics GmbH; Abdul Kader, George Salomon, Nalco Water, An Ecolab Company; Brad DeSplinter, TPM Precise control of ceramic slurry viscosity and density
is essential for achieving consistent shell quality in foundry processes. Traditional methods rely on manual measurements using efflux cups for viscosity and laboratory density meters. Since September 2024 Texas Precision Metalcraft has implemented a combined system utilizing Rheonics' SlurrySense with Cleanwave self-cleaning sensor for real-time density and viscosity measurement in a slurry tank, integrated with Ecolab's 3D TRASAR digital process monitoring and control system. This automated approach has significantly reduced operator intervention and minimized the need for manual cup measurements. The continuous, live viscosity and density data provided by the system enables operators to validate traditional cup-second readings, preventing unnecessary dilution adjustments. This implementation has demonstrated substantial time and labor savings, while simultaneously improving slurry consistency, underscoring the advantages of real-time data for enhancing and supplementing traditional measurement techniques. Keywords: Ceramics and Mold Making
Agenda, Continued on pg 20
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40
