In the present scenario, the dimensional accuracy and surface roughness of casted complex shape products have become a critical issue to reduce machining cost in terms of time, price and scrap materials. So, different types of casting processes have been introduced. One of the important casting process is Investment Casting Process with Expandable Polystyrene Pattern, instead of wax pattern. In this casting process, the shell is made by decomposition of Expandable Polystyrene pattern with the application of heat. During the foam removal process, several problems have been created such as bending, expansion, distending and crack of the shell. In this paper, Zirconium Flour and Mullite sand (Aluminium-Silicate) have been introduced as coating materials with different ratio, with binder as Sodium Silicate and Potassium Silicate. Twelve samples have been prepared and the densities and viscosities of each sample are calculated. Twelve shells are also generated. For selection of best shell material composition, Analytical Hierarchy Process (AHP) is used. Sample 7 has the best result. Also, Potassium Silicate is found better than Sodium Silicate as binder, to reduce distending of shell, cracks, etc. and to increase surface finish and strength to weight ratio of shell.

">

Optimization of Coating Materials Used on Expandable Polystyrene Pattern in Investment Casting Process

Girendra Bhati*, Sudhir Kumar**, Ajay Kumar***, Daizy Rajput****
* Assistant Professor, Noida Institute of Engineering Technology, Greater Noida, Gautam Budh Nagar, U.P., India.
** Professor, Noida Institute of Engineering Technology, Greater Noida, Gautam Budh Nagar, U.P., India.
*** Associate Professor, Noida Institute of Engineering Technology, Greater Noida, Gautam Budh Nagar, U.P., India.
**** Lecturer, Noida Institute of Engineering Technology, Greater Noida, Gautam Budh Nagar, U.P., India.
Periodicity:February - April'2013
DOI : https://doi.org/10.26634/jme.3.2.2211

Abstract

In the present scenario, the dimensional accuracy and surface roughness of casted complex shape products have become a critical issue to reduce machining cost in terms of time, price and scrap materials. So, different types of casting processes have been introduced. One of the important casting process is Investment Casting Process with Expandable Polystyrene Pattern, instead of wax pattern. In this casting process, the shell is made by decomposition of Expandable Polystyrene pattern with the application of heat. During the foam removal process, several problems have been created such as bending, expansion, distending and crack of the shell. In this paper, Zirconium Flour and Mullite sand (Aluminium-Silicate) have been introduced as coating materials with different ratio, with binder as Sodium Silicate and Potassium Silicate. Twelve samples have been prepared and the densities and viscosities of each sample are calculated. Twelve shells are also generated. For selection of best shell material composition, Analytical Hierarchy Process (AHP) is used. Sample 7 has the best result. Also, Potassium Silicate is found better than Sodium Silicate as binder, to reduce distending of shell, cracks, etc. and to increase surface finish and strength to weight ratio of shell.

Keywords

Expandable Polystyrene Pattern, Zircon flour, Mullite, Potassium silicate, Sodium silicate, Density, Viscosity, AHP.

How to Cite this Article?

Bhati, G., Kumar, S., Kumar, A., & Rajput, D. (2013). Optimization of Coating Materials Used on Expandable Polystyrene Pattern in Investment Casting Process. i-manager's Journal on Mechanical Engineering, 3(2), 21-32. https://doi.org/10.26634/jme.3.2.2211

References

[1]. R. C. Reed (2006). “The superalloys fundamentals and applications”. Cambridge University Press;
[2]. S. M., Afazov, A., A. Becker, T.H., Hyde (2011). “FE prediction of residual stresses of investment casting in a Bottom Core Vane under equiaxed cooling” Journal of Manufacturing Processes 13. 30–40.
[3]. S. U. Behm, K. L. Gunter, J. W. Sutherland (2003). “An Investigation into the Effect of Process Parameter Settings on Air Emission Characteristics in the Lost Foam Casting Process” Transactions of the American Foundryman Society ,1-10
[4]. Yu Yong Chen, Yan Fei Chen, Shu Long Xiao, Jing Tian, Li Juan Xu (2011). “Preparation of Ceramic Moulds with Zirconia Coatings for the Investment Casting of TiAl Alloys” Advanced Materials Research, 146-147, 499. doi: 10.4028/www.scientific.net/AMR.146 147.499.
[5]. Chun Ju Huang, Ming C Leu, L Von Richards (2007). “Investment casting with ice pattern and comparison with other type of Rapid Prototype pattern” Shape Casting: 2nd International Symposium, 267-274.
[6]. E. H. Niemann (1980). “Expandable polystyrene pattern material for the lost foam process”. American. Foundryman Soc. Trans. 88, 793–799.
[7]. S. Shivkumar (1993). “Casting characteristic of aluminum alloys in the EPC process”. American Foundryman Soc. Trans. 101, 519–524.
[8]. T.V. Moilbog, H. Littleton, (2001). “Experimental simulation of pattern degradation in lost foam”. American Foundryman Soc. Trans. 109, 1523–1555.
[9]. J. H. Barron. (1965). “Full mould process—the direct approach to metal casting”, American Foundryman Soc. Trans., 73, 129–132.
[10]. S. Kumar, P. Kumar, and H. S. Shan (2007). “Effect of evaporative pattern casting process parameters on the surface roughness of Al–7% Si alloy castings”. J. Mater. Process. Technol., 182, 615–623.
[11]. Zagorka Ac´imovic´ Pavlovic´, Ljubis?a Andric´, Vladan Milos?evic´ , Sonja Milic´evic´ (2011). “Refractory coating based on cordierite for application in new evaporate pattern casting process” Ceramics International 37, 99–104.
[12]. S. Kumar, P. Kumar, H.S. Shan, (2004). “Effect of filler material in zircon flour coating used in evaporative pattern casting process”, Indian Foundry J. 50, 34–40.
[13]. H. Ohnishi, K. Maeda, T. Nakamura, and T. Kawanami, (1990). "High Temperature Mechanical Properties of Mullite Ceramics"; In. Ceramic Transaction, Vol. 6, 605-12.
[14]. Dong Kyu Kim and Waltraud M. Kriven (2004). “Mullite (3AI203 2SiO2) Aluminum Phosphate (AIPO4), Oxide, Fibrous Monolithic Composites. J. Am. Ceram. Soc., 87, 151794-803.
[15]. Sudhir Kumar, Pradeep Kumar, H.S. Shan (2008) . “Characterization of the refractory coating material used in vacuum assisted evaporative pattern casting process”. Journal of Materials Processing Technology. PROTEC12213 1–8.
[16]. H. Tanaka, S. Sawai, K. Morimoto, K. Hisano (2001). “Measurement of spectral emissivity and thermal conductivity of zirconia by thermal radiation calorimeter”. Journal of Thermal Analysis and Calorimetry; 64, 867–72.
[17]. G.W. Parmelee, H. Thurnauer, (1935). “Some effects of additions to a talk body”, Bull. Am. Ceram. Soc. 14, 69.
[18]. Lj. Trumbulovic, Z. Acimovic, Z. Gulisija, Lj. Andric, (2004). “Correlation of technological parameters and quality of castings obtained by the EPC method”, Mater. Lett. 58, 1726–1731
[19]. T.V. Molibog and H. Littleton (2001). “Proceedings of Lost Foam Casting”, AFS, Dallas, Texas, 2001, 71
[20]. Lee Heeseok, Kwak, Wikil and Han Ingoo (1995). “Developing a business performance evaluation system: an analytic hierarchical model”, The Engineering Economist, Vol.40, No.4, 343 357.
[21]. T. L. Saaty. (1994). “Fundamentals of Decision Making and Priority Theory with the Analytic Hierarchy Process”, RWS Publications, Pittsburgh, PA.
[22]. Saaty, T.L. (1980). “The Analytic Hierarchy Process”, McGraw Hill, New York, NY.
If you have access to this article please login to view the article or kindly login to purchase the article

Purchase Instant Access

Single Article

North Americas,UK,
Middle East,Europe
India Rest of world
USD EUR INR USD-ROW
Pdf 35 35 200 20
Online 35 35 200 15
Pdf & Online 35 35 400 25

Options for accessing this content:
  • If you would like institutional access to this content, please recommend the title to your librarian.
    Library Recommendation Form
  • If you already have i-manager's user account: Login above and proceed to purchase the article.
  • New Users: Please register, then proceed to purchase the article.