International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 10, October 2012)
Evaluation of Primary Slurry Used in Ceramic Shell Investment
Casting Process
Balwinder Singh1, Pradeep Kumar2, B.K.Mishra3
1
Associate Professor Department of Mechanical Engineering, Punjab Technical University GZS Campus Punjab 151001,
India
2,3
Professor Department of Mechanical and Industrial Engineering, Indian Institute of Technology Roorkee, Roorkee- 247667,
India
Abstract — Ceramic shell investment casting process is
used to produce high quality metal products with relatively
close dimensional tolerances. The refractory primary slurry
that is applied to the surface of the pattern assembly, to pick
up its surface details plays a very important role in ceramic
shell investment casting process (CSICP). It produces a
smooth, acceptable surface finish of the ceramic shell mould,
which in turn is transmitted to the casting. Zircon flour,
though costly, is being used as a primary slurry material in
the ceramic shell investment casting process. To reduce the
cost of primary slurry material, some refractory filler
materials were added with the zircon flour. The Scanning
Electronic Microscopy (SEM) technique has been used to
study the surface morphology of ceramic shell prepared from
primary slurry. Parameters like viscosity and plate weights of
the slurries have been measured. The results reveal that the
fused silica with colloidal silica binder when used as a filler
material in zircon flour primary slurry gives the best results
with respect to above properties.
Keywords — Primary slurry, filler materials Plate weight,
viscosity, Scanning Electronic Microscopy (SEM)
I. INTRODUCTION
The higher demand for investment casting lies in its
ability to produce complex shapes, with high dimensional
accuracy, good surface finish and good castability on large
variety of alloys. Due to technological advances, ceramic
shell investment casting process has become the most
versatile modern metal casting technique. In this process,
the application of slurry and stucco (refractory particles) on
wax pattern assembly is repeated, with drying between
each successive coat, until a shell mould of sufficient
thickness is achieved. The first layer is normally fine
primary slurry so that a good surface finish on the casting
will be obtained. Subsequent layers are made up of ceramic
slurry and refractory granules. The shell will normally be
made up of between five and eight layers depending on the
cooling rate required and the subsequent metallurgical
properties [1]. Following completion of shell build, the
expendable pattern material is removed usually by the
action of heat and/or steam.
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The dewaxed ceramic shell mould is fired at a
temperature of the order of 1,000°C, to develop the
maximum ceramic bond and molten metal is poured
immediately upon removal from the firing furnace [1]. The
quality of ceramic shells is dependent on the slurry and
shell materials as well as the process by which the shells
are built [2]. A good slurry composition will not be
guaranteed to produce smooth and defect free shell if the
slurry is prepared in an inadequate manner. Control
procedures for slurries vary considerably among foundries,
reflecting in part the wide range of specifications that
different shops work to, depending on their product line
[3]. Therefore, slurry control is one of the most important
operations of the investment casting process as reported by
Michael J Hendricks [4]. Viscosity, density, binder,
filler/sol ratio, wetting agent and antifoaming agents are the
important parameters of the slurry to be controlled. An
appropriate slurry viscosity should be maintained to avoid
shell problems such as cracking. The primary coat must
withstand pressure from expanding wax as it is heated
during the wax removal stage as well as survive the rigors
of handling during the shell building process [4]. The
fundamental relationship between variations in the raw
materials, the slurry and the mould is still being developed
and progress in this area will only continue with
commitment of the industry to regular raw material testing
and the full use of resulting data in the analysis of casting
results. In present investigations the properties of the zircon
flour/fused silica slurry were characterized and the main
factors controlling the viscosity, plate weight were
identified.
II. FUNCTION OF PRIMARY SLURRY
The refractory primary slurry plays an intimate role in
the ceramic shell investment casting process. It provides
refractory protection to ensure no metal penetration and
smooth surfaces of shell mould. The primary coat
refractory must be non reactive with binder used to produce
slurry as well as with alloy being poured.
 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 10, October 2012)
Surface finish will be an important characteristic of the In general, signal to noise (S/N) ratio (h, dB) represents
casting; great attention must be given to the nature of the quality characteristics for the observed data in the Taguchi
ceramic filler. The main factors determining the surface design of experiments. Depending on the experimental
quality of the ceramic shell mould for investment casting of objective, there are several quality characteristics. In the
metal alloys include the density of the ceramic powder case of slurry viscosity and plate weight, higher values of
compact and viscosity of the primary slurry [5]. The them are desirable. These S/N ratios in the Taguchi method
objective of any slurry composition is to produce stable are called as the higher-the-better characteristics and are
slurry. Slurry mixing has a remarkable effect on the surface defined as follows.
quality and strength of the shell. There are many factors From the S/N ratio, the effective parameters having
like silica type and level, refractory type, flour particle size influence on process results can be seen and the optimal
distribution, solids loading, viscosity, plate weight, etc that sets of process parameters can be determined. Design of
play a role on the final ceramic shell properties. Selection experiment (DOE) has been a very useful tool to design
of any refractory filler material for shell making is and analyze complicated industrial design problems.The
dependent on a wide variety of factors which can affect the non-liner behavior, if exists, among the process parameters
properties of investment slurry, shell and casting and also can only be studied if more than two levels of the
the economy of the process [4]. In general zircon flour is parameters are used. Therefore, each parameter was
used as a primary slurry material in the ceramic shell analyzed at three levels. The selected number of process
investment casting process but it is very costly. Roberts [6] parameters and their levels are given in Table1.
showed that by using slurry of seven millimicron sol. Table-1
containing fused-silica grains of three different particle Trial levels factors in the Taguchi’s L9 OA experiment
sizes the resultant structure was stronger in both the green
and fired states. Fused silica and alumina silica have Process Process Level 1 Level 2 Level 3
become the two most widely used refractories for ceramic Parameter Parameters
shell investment casting as a result of their relatively designation
optimum characteristics of performance and material costs.
A Zircon flour 120 180 240
(gm)
III. EXPERIMENTAL DETAILS
Primary Slurry preparation. B Fused silica 60 120 180
The raw materials (refractory, binder, wetting agent, and (gm)
antifoam) used to make slurry play a major role in
C Filler/sol ratio 2.5 3.0 3.5
determining the overall final ceramic shell characteristics.
(gm/ml)
Suitable choice of the ceramic materials can lead to smooth
surface finish, high accuracy of the metal castings. In the D Catalyst (ml) 2 3 4
present work Taguchi’s parameter design approach is used
to study the effect of process parameters on the slurry
viscosity and primary coatings in ceramic shell investment
casting process. The Taguchi design method is a simple Particle Size: Zircon flour 200 US mesh, Fused silica 325 US mesh;
and robust technique for optimizing the process parameters Mixing time: 25 hours, Pattern material: wax blend, Sol: Colloidal
[8-9]. In this method, main parameters which are assumed silica 30%, Catalyst: 50% n-octyl alcohol and 50% triton,
to have influence on process results are located at different Temperature: 30 ± 2 oC.
rows in a designed orthogonal array. With such an
arrangement completely randomized experiments can be
conducted.

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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 10, October 2012)
Table-2 Mixture of zircon flour, fused silica powder as filler,
The L9 (34) OA (parameters assigned) with response colloidal silica as binder along with wetting and
antifoaming agents (Catalyst) were used for investigating
Sr Run Parameters Viscosity ( Raw data) S/N the slurry parameters
No Order Trial Ratio Details of slurry composition and their levels are given
Conditions (db)
in table 1. An electronic balance (Metler, LC 0.1 mg) was
A B C D R1 R2 R3
used for the measurement of refractory powders. Density
1 2 3 4
of the slurry was determined with the use of conventional
1 3 1 1 1 1 1506 1510 1508 63.57
method by measuring mass and volume. Viscosity was
measured using the Brookfield Digital viscometer Model
2 7 1 2 2 2 1540 1550 1545 63.78
DV-II+ (Accuracy: ±1.0% of range, speed: 0.01 to 200
RPM, reproducibility: ±0.2%). The viscometer is of
3 5 1 3 3 3 1604 1606 1600 64.10 rotational variety type. It measures the torque required to
rotate an immersed element (spindle) in a fluid. The spindle
4 1 2 1 2 3 1680 1683 1686 64.52 is driven by a synchronous motor through a calibrated
spring; the deflection of the spring is indicated by a pointer
5 4 2 2 3 1 1780 1778 1792 65.02 and dial (digital display). All the values of viscosity were
measured at a constant speed. The slurry has to be kept
6 6 2 3 1 2 1825 1830 1812 65.21 under continuous stirring throughout its use in the coating
process. This is necessary in order to prevent the
7 9 3 1 3 2 1920 1932 1935 65.70 settling/separation of the heavy filler materials used in the
slurry and to maintain the homogeneity of the slurry
8 2 3 2 1 3 1962 1960 1948 65.83
throughout its use. In the shell building process, after the
cluster is dipped in the slurry, they are stuccoed with zircon
sand. Three shells are produced from each slurry using
9 8 3 3 2 1 2074 2075 2070 66.33
calcined fused silica as back up stucco (mesh sizes-16 +30
T = overall mean of Viscosity = 1767.07 cp and -30 +80). The scanning electronic microscopy (SEM)
R1, R2, R3 represent responses value for three repetitions of each analysis of filler particles and ceramic shell surface
trial. The 1’s, 2’s, and 3’s represent levels 1, 2,3 and 4 of the (primary coating) was done using the apparatus JEOL-T20
parameters, which appear at the top of the column. Yij are the with 1000 magnifications. The samples were ultrasound
measured values of the quality characteristic (response). deaglomerated in etalon for 10 minutes, and then gold
spattered. The optical profilometer was used to measure
For the sake of simplification, the second order Surface Roughness values of the ceramic shell surface after
interactions among the parameters were not considered. dewaxing. Several Ra values were taken at different
Each three level parameter has 2 degree of freedom (DOF) locations on the shell surface.
(Number of levels - 1), the total DOF required for four
parameters each at three levels is 8 [= 4 x (3-1)]. As per IV. EVALUATION OF SLURRY PROPERTIES
Taguchi’s method the total DOF of selected OA must be
greater than or equal to the total DOF required for the The effect of slurry parameters on the plate weight
experiment. So an L9 OA (a standard 3-level OA) having 8 primary slurry thickness was evaluated and optimum slurry
(=9-1) degree of freedom was selected for the present composition/ conditions for minimizing the surface
analysis (Table 2). In the present investigations, primary roughness of primary coating were determined. Four
slurries have been formulated using a mixture of zircon controllable factors of the slurry preparation process were
flour and fused silica powder as filler and colloidal silica as studied at three levels each. The resultant slurries were
binder. characterized by measurements of viscosity and plate
Mixture of triton (wetting agent) and n-Octyl alcohol retention rate. The influence of solids loading and particle
(antifoaming) used as Catalyst. Details of slurry shape on the viscosity and plate retention rate was also
composition and their levels are given in table 1. In order to investigated. Plate weight is a measurement used to
achieve consistency of slurry characteristics correct determine slurry pickup on a metal plate. It is useful in
preparation and maintenance must be ensured. controlling slurries not only for slurry coverage and
adhesion, but also for rheology or flow characteristics.
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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 10, October 2012)
It is mainly used on primary slurries but can also be used Refractory properties, i.e. density, morphology (particle
on backup slurries. The plate weight can influence the shape), particle size and distribution all influence slurry
porosity or permeability of the primary slurry and primary rheology. Fused silica prime slurries drain and level slowly
slurry thickness, which can cause stucco penetration. Plate compared to all zircon slurry.
weight is one method used to indirectly measure thixotropy
and film thickness. VI. CONCLUSIONS
The Scanning Electronic Microscopy (SEM) technique Primary slurry composition and its processing can be
has been used to study the surface morphology of powder considered as one of the major component for making
particles as well as primary slurry. Optical profilometer has ceramic investment shell moulds of precision components.
been used to measure the surface roughness of the shells Within the range of test conditions employed, the following
(primary slurry). Variation in primary slurry thickness with conclusions have been drawn:
plate weight (Ceramic Retention Test) was calculated for The optimal levels of Zircon flour, fused silica, filler/sol
each slurry. All formulas are based on weight rather than ratio and the catalyst for maximum plate weight
volume and all components are weighed by electronic corresponds to the highest S/N ratio and Zircon flour,
balance. The following properties have been studied in the filler/sol ratio and the catalyst significantly affects the
present work slurry plate weight. The surface condition of primary coat
Viscosity: Viscosity was calculated using the Brookfield i.e. shell surface can be improved by increasing the
DV-II+Viscometer (accuracy: ±1.0% of range, filler/sol ratio in the slurry to 3.5.
reproducibility: ±0.2%, speed: 0.01 to 200 rpm). Viscosity
was found to be lower when shear force was working and
higher when shear force was in operation [2]. All the values
were measured at constant speed.
Plate weight: The ceramic retention rate R was calculated
using the equation
R= (Wd- Wp)/S . . . . . . . . . . . . (1)
Where Wp is the undipped plate weight, Wd the dipped
weight of the plate, and S the surface area of the plate [7].
The thickness of the primary slurry layer H can be derived
from the equation
H= (Wd -Wp)/DS=R /D . . . . . . . . . (2) Where D is
the density of the slurry.
Scanning Electronic Microscopy (SEM): Scanning
electronic microscopy, SEM analysis was done using the
JEOL-T20 with 500 and1000 magnifications. The samples Figure 2: SEM micrograph showing the surface morphology of the
were ultrasound deaglomerated in etalon for 10 minutes, shell.
and then gold spattered
The result reveals that the surface condition of shell can
V. CONFIRMATION EXPERIMENTS be improved by increasing the Viscosity and hence plate
weight, corresponding to higher filler loading in the slurry.
Three confirmation experiments were conducted at the Confirmation experiments were conducted at an optimal
optimum composition of the slurry parameters. The zircon condition showed that the surface quality of the ceramic
flour was set at the third level (A3), fused silica powder at investment shell moulds were improved significantly.
the third level (B3), filler/sol ratio at third level (C3) and SEM micrograph showing the surface morphology of the
catalyst was kept at the first level (D1). The average shell (primary coating) made from slurry with optimum
viscosity of the slurry 2080 cp which was within the composition is shown in Figure 2. This Micrograph shows
confidence interval of the predicated optimal of viscosity. that the shell is having a uniform, smooth and homogenous
Refractories have the greatest influence on the system appearance.
behavior because it is usually the largest component of the
system.

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 International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, Volume 2, Issue 10, October 2012)
REFERENCES titanium alloys‖ International Journal of Materials and Product
Technology, VOL.2, 2001, p 793-798.
[1] P. R. Beeley and R. F. Smart, Investment Casting, 1st Edition, The
University Press,Cambridge, UK, 1995. . [6] W.O.Roberts, ―Factors affecting Shell Strength‖ 25th ICI
Conference 1977, Denver, Colorado; U.S.A.
[2] Singh, Balwinder, Kumar, Pradeep, Mishra, B .K. (2006)
―Parametric Optimization of Slurry Composition used in Ceramic [7] Singh, Balwinder, Kumar, Pradeep, Mishra, B .K. (2008), ―Effect of
Shell Investment Casting Process through Taguchi Method‖ Indian Slurry Composition on Plate Weight in Ceramic Shell Investment
Foundry Journal, Vol. 52, No.10, pp. 25-33. Casting‖ Journal of Materials Engineering & Performance JMEP-06-
12-0401, Vol 17,No.4/August 2008 pp 489-498
[3] Investment Casting ASM Hand Book Vol.15, p 253-257.
[8] Ross P. J., 1988, ―Taguchi techniques for quality engineering‖,
[4] Michael J Hendricks Processing and firing influences on ceramic McGraw-Hill Book Company, New York.
shell materials. Foundry Trade Journal –June 1991
[9] Roy R. K., 1990, ―A primer on Taguchi method‖, Van Nostrand
[5] Cui, Y.Y.; Yang, R. ―Influence of powder-size matching on the Reinhold, New York.
surface quality of ceramic mould shell for investment casting of

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Figure. 1: Slurry Mixer [2, 7]. (1) Impeller Eye (2) Slurry (3) Steel Tank (4) Impeller Rod (5) Cover Plate (6) Fixture (7) Speed Controller (8) Electric
Motor (9) Timer (10) Coupling Plate (11) Horizontal Barrel (12) Lever (13) Vertical Barrel (14) Extension rod (15) Lock Nut (16) Stand and (17) Base
Channel.

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