Preliminary Agenda Abstracts TUESDAY, AUGUST 23, 2022, con’t.
8:40 a.m. – 9:20 a.m. Enablers for Driving Forward a Precision Investment Casting World Class Foundry Carlos Olabe, EICF Executive Director Precision Investment Casting is a technology able to provide solutions satisfying a variety of engineering applications in fields such as Energy, Aerospace, Automotive, Oil & Gas, Bio Medical …etc. improving performance and contributing to social welfare. The industry as we know it today has its origins just at the time of WWII – The developments in 80 years has positioned the industry delivering solutions for the demanding challenges that each different application segment requires, transforming it in a High Technology Industry. Under this scenario what are the key elements necessary to make a Precision Investment Casting Foundry competitive? and what are the enablers to make it a World Class Foundry? What are the challenges IC must overcome to cope with the evolution in the forthcoming requirements? This paper shall be reviewing those key factors and enablers based on the author´s experience in launching an aerospace brand-new foundry and the analysis and observation of the many different foundries that he has had the opportunity to know and deal with.
9:20 a.m. – 10:00 a.m. A Novel Prime Coat Slurry Mineral for Aluminum Investment Castings Steven Ashlock, Kyanite Mining Corp., Booth No. 324 The selection of a face coat refractory material to be used
in investment casting is crucial when evaluating “as-cast” quality. The face coat material must be refractory, as it needs to be able to withstand the “super heat” of the molten metal to avoid defects caused by mold-metal reactions. Ideally, the material would be non-wetting so that the molten metal never has a chance to penetrate the porosity of the prime coat. The prime coat slurries must have adequate flow-behavior (rheology) to ensure the casting maintains the intricate detail of the pattern. Zircon is nearly always used in prime coat slurries and prime coat stuccos. This is primarily because zircon is a stable refractory mineral and can withstand the superheats used to cast stainless alloys. However, in applications where the alloy temperature is much lower than iron or nickel- base superalloys, high temperature refractoriness may not be needed; e.g. investment casting aluminum.
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In aluminum castings, the backup materials may differ from steel, but the prime coat material is often the same: zircon. Zircon is commonly used even though aluminum alloys melt at significantly lower temperatures than their steel counterparts. Molten aluminum is corrosive and readily reacts with most refractories through the reductive action of aluminum. This corrosiveness causes mold-metal reactions and leads to surface defects, increasing finishing labor. Zircon does a good job resisting this corrosion but comes at a significant cost and is over-kill for aluminum casting applications. Kyanite Mining Corporation has recently developed a new prime coat slurry mineral alternative that is both refractory enough to withstand the temperature of aluminum superheat and exhibits non- wetting characteristics with molten aluminum, leaving a smooth as-cast surface. This paper will discuss the viability of this new prime coat slurry for aluminum investment castings through laboratory testing and a foundry case study.
10:00 a.m. – 10:20 a.m. BREAK
10:20 a.m. – 11:00 a.m. Evaluation of Printed Wax Pattern Molds Tom Mueller, Mueller Additive Mfg Solutions The use of printed investment casting patterns has almost
universally changed the way that prototype investment castings are created. Eliminating the need to first create tooling has enabled manufacturers to make prototypes faster and at lower cost and allowed the evaluation of multiple alternative designs before making the large investment in tooling.
In addition,
by using printed patterns, investment casting can be a cost- effective means for producing low numbers of metal parts. Previously, the cost of tooling prevented investment casting from being a viable option. However, for nearly all types of printed patterns, a slightly
different casting process is required which is more difficult and more expensive than that used for molded wax patterns. Unfortunately, these process modifications make it difficult for a foundry to run a mix of printed and molded wax patterns. Once the first coat of the shell is applied, all shells look alike, and it can be very difficult to keep track of which shells use which casting process. As a result, it can be difficult to use printed patterns for more than a few prototype castings. The recent development of AM materials with both high heat deflection temperatures and high strength have enabled
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28 ❘ May 2022 ®
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