Improved sol based ceramic moulds for use in investment casting

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http://eprints.org/relation/isVersionOf http://etheses.bham.ac.uk/id/document/22912 http://eprints.org/relation/isVolatileVersionOf http://etheses.bham.ac.uk/id/document/22912 http://eprints.org/relation/isIndexCodesVersionOf http://etheses.bham.ac.uk/id/document/22912 archive 4031 disk0/00/00/07/88 2013-01-08 17:40:34 2019-01-23 09:52:51 2013-01-08 17:40:34 thesis show 0 Jones Samantha Marquis Peter ftp://ubira.bham.ac.uk/eTheses/788_Jones/ University of Birmingham Improved sol based ceramic moulds for use in investment casting unpub TN TS 40fac_eng Investment casting An investigation has been carried out into the mechanisms of failure of silica bonded investment casting moulds, with the aim of reducing failure rates for larger components. The analysis begins with a detailed microstructural examination of a current commercial mould system using scanning electron microscopy and other allied analysis techniques. The mould structure is shown to be nonuniform and unpredictable, with poor packing of the ceramic constituents leading to a non-uniform porosity network. The structure and distribution of the binder is also established and this indicates that the major load bearing points within the mould consist of thin areas of silica. As such, the overall performance of the mould is directly related to that of the silica itself. This binder is shown to contain impurity elements leached from the ceramic filler at various stages during mould manufacture. These elements alter the phase composition and thermal properties of the binder. Mould temperature profiles for a range of casting sizes have been measured and used to illustrate the relationship between metal weight and maximum temperature attained within the mould section. The profiles are also used to investigate the creep response of silica based binders. It is found that a combination of high temperatures and creep within the silica phase is responsible for the casting defects found with larger components. From these observations, a prediction is made regarding failure mechanisms and suggested remedial action. The thermal properties of several commercial water based binders are evaluated and the suitability of each as an alternative binder is discussed. 1993-12 1993-05 graduation eng other Scanned by Hollingworth & Moss This unpublished thesis/dissertation is copyright of the author and/or third parties. The intellectual property rights of the author or third parties in respect of this work are as defined by The Copyright Designs and Patents Act 1988 or as modified by any successor legislation. Any use made of information contained in this thesis/dissertation must be in accordance with that legislation and must be properly acknowledged. Further distribution or reproduction in any format is prohibited without the permission of the copyright holder. Doncasters Group Ltd public 332 University of Birmingham School of Metallurgy and Materials d_ph stfc 1993-12 graduation