Effect of Slurry Composition on Plate Weight in Ceramic Shell Investment Casting |
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Authors: | Balwinder Singh Sidhu Pradeep Kumar BK Mishra |
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Affiliation: | (1) Department of Mechanical & Industrial Engineering, IIT, Roorkee, 247 667, India |
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Abstract: | This paper deals with the study of the effect of primary slurry parameters on the plate weight (ceramic retention test) in
ceramic shell investment casting process. Four controllable factors of the zircon flour and fused-silica powder based slurries
were studied at three levels each by Taguchi’s parametric approach and single-response optimization of plate weight was conducted
to identify the main factors controlling its stability. Variations in coating thickness with plate weight were calculated
for each slurry and ceramic shell moulds were made on wax plate using primary slurry and coarse fused-silica sand as stucco.
The Scanning Electronic Microscopy (SEM) technique has been used to study the surface morphology of zircon flour and fused
silca powder particles as well as primary coating (shell surface). X-ray Diffraction (XRD) analysis was done to identify the
various phases present in the ceramic slurry coating. Optical profilometer has been used to measure the surface roughness
of the shells. The result reveals that the surface condition of shell can be improved by increasing the plate weight, corresponding
to higher filler loading in the slurry. Confirmation experiments were conducted at an optimal condition showed that the surface
quality of the ceramic shell mould were improved significantly. Castings were produced using Al-7%Si alloy in recommended
parameters through ceramic shell investment casting process. Surface roughness of the produced casting were measured and presented
in this paper. |
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Keywords: | coating thickness plate weight primary slurry surface roughness |
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