Sukhoiri Khoiruddin, Imang Eko Saputro, Cheng-Fu Huang, Sheng-Chan Lee, Chien-Wei Chan, Yiin-Kuen Fuh
Ceramic shell molds are essential in investment casting, providing strength, precision, and dimensional accuracy. This study investigates the reinforcement of standardized shells with silicon carbide (SiC) powder to improve mechanical, thermal, and physical properties. The base shell composition consists of zircon (ZrSiO4) powder with a Levasil FO830 binder for the face coat and mullite (3Al2O3·2SiO2) powder with a colloidal silica binder for the backup layers. SiC powder is added in microscale (4000 mesh) and nanoscale (10 000 mesh) sizes at 5–25 wt% within a 4.5-layer thickness. These results were compared with those of the original shells, which had 4.5–8.5 layers. The main objective is to develop an optimized SiC-reinforced shell with fewer layers while maintaining performance. The t-test results show that all properties are significantly improved in the SiC-reinforced shells compared to the original shell, where the smaller SiC particles and higher concentrations reduce porosity, increase the modulus of rupture and heat transfer coefficient, but lower gas permeability. Figures of merit analysis reveals that 4000 mesh SiC at 5, 10, and 25 wt% within 4.5 layers can replace original shells with 5.5, 6.5, and 8.5 layers, respectively. These findings offer valuable insights for reducing costs and optimizing shell formulations in investment casting. © 2025 Wiley-VCH GmbH.
Department of Mechanical Engineering, National Central University, No. 300, Zhongda Road, Zhongli District, Taoyuan City, 320317, Taiwan; Department of Mechanical Engineering, Brawijaya University, No. 167, Mayjend Haryono Street, Malang City, 65145, Indonesia; GlobalTek Fabrication Co., Ltd., Xinwu Factory, Taoyuan City, 327001, Taiwan
