Nov. 29, 1960 T.

OPERHALL ETAL 2,961,751

CERAMIC METAL CASTING PROCESS
Filed Jan. 13, 1958 3 Sheets-Sheet 1

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CERAMIC METAL CASTING PROCESS
Filed Jan. 13, 195B 3 Sheets-Sheet 2

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Nov. 29, 1960 'r. OPERHALL EI'AL 2,961,751
CERAMIC METAL CASTING PROCESS
Filed Jan. 13, 1958 3 Sheets-Sheet 5

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 2,961,751
United States Patent 0 Patented Nov. 29, 1960

2
move the wax and to mature the ceramic materials, and
Fig. 5 is a schematic sectional elevational view of the
metal melting furnace and the mold clamped thereon.
2,961,751 The invention will hereinafter be described with refer
CERAMIC METAL CASTING PROCESS 5 ence to an illustrative practice of the invention, it being
Theodore Operhall, Charles W. Schwartz, and Dickson understood that variations may be made within the skills
Van Schoik, Whitehall, Mich., assignors, by mesne as of the art.
signments. tn Misco P.C., lnc., New York, N.Y., a cor Preparation of the cluster
poration of New Jersey To the point where a cluster 10 is formed of the wax
10 patterns 12 mounted between wax runners 14 in com
Filed Jan. 13, 1958, Ser. No. 708,628
munication with a wax spout in the form of a crucible
17 Claims. (Cl. 22-496) 16, the process is almost identical with the conventional
investment casting processes as de?ned in the Collins
Patent No. 2,380,945, Feagin et al. Patents Nos. 2,439,207,
This invention relates to the fabrication of metal cast 15 2,441,695 and 2,521,839, and in the Operhall Patent No.
ings and it relates more particularly to a metal casting 2,806,271.
process and materials for use in same embodying some Dip coating composition
of the elements of an investment casting process with
some of the elements of a shell molding process while 8000 cc. colloidal silica
eliminating many of the limitations of each of the proc (30% grade)
esses to provide a new and improved procedure for the (speci?c gravity 1.198)
production of metal castings. 165 pounds zircon
Both the investment casting process and the shell mold (99% through 325 mesh)
ing process are well known to those skilled in the art (65-67% ZnO2, 34-32% SiO2)
such that detailed description thereof by way of introduc 25 6150 cc. water
tion shall be unnecessary here. Sul?ce it to say that 110 grams sodium ?uoride
the investment casting process ?nds objections in the Application of ?rst dip coat
?eld from the standpoint of the high cost of materials The cluster 10 of wax patterns 12, carried by a handle
required in the preparation of the investment and mold embedded in the crucible de?ning the pouring spout 16
for casting; in the large amount of highly skilled labor 30 of the cluster, is ?rst inspected to remove dirt, wax
required for preparation of the wax patterns and the ?akes and other objects which may have adhered to the
mold, and in the utilization thereof in the casting process, surfaces of the wax patterns and, if allowed to remain,
and in the high percentage of scrap which generally char would impair the preparation of a good mold, thus lead
acterizes the investment process for the production of ing to an imperfect casting. The cleaned cluster is then
metal castings thereby to prevent reduction in cost of 35 immersed into the slip in a manner to coat all of the sur
castings so produced. faces of the cluster with the exception of the lip of the
While shell molding with an organic resinous binder crucible. To promote the removal of bubbles from the
eliminates or rather minimizes some of the more objec cluster design, it is desirable to rotate the cluster while
tionable features of the investment casting process, such
shell molding process, as it is practiced today, has other 40 immersed in the slip.
When fully coated, the cluster can be removed from
characteristics which are objectionable from the stand the tank to drain. During drainage, the cluster can be
point of the desire to produce acceptable castings at high inspected to detect air pockets which can be eliminated
yield with a minimum amount of labor, materials and by directing a stream of air onto the de?cient portions
cost. and thereafter allowing the slurry of the dip coat to flow
Thus it is an object of this invention to provide a new 45
and improved method for the production of metal cast onto the blown area. While the cluster is being drained,
ings and it is a related object to provide new and im
it should be held in different planes designed to achieve
uniform coating on all surfaces. In general, drainage
proved materials for use in the practice of same. should be completed within a few minutes but, in any
More speci?cally, it is an object of this invention to
event, in less time than would allow the dip coat to
provide a new and improved metal casting process which, 50 gel or dry to the extent that a good stucco coat cannot
while embodying some of the desirable features of the
shell molding and investment casting processes, eliminates be applied.
First stucco coat
many of the undesirable characteristics of each and, in
addition, provides means whereby a higher yield of good Stucco combination-Alundum (100% through 50 mesh
castings can be achieved at less cost from the standpoint 55 with less than 3% through 100 mesh—better than 90%
of the cost of materials, the amount of labor, time and between 60 and 80 mesh)
space, as well as equipment required for manufacture. Application of stucco coat
These and other objects and advantages of this inven
tion will hereinafter appear and for purposes of illustra After the uniformity of coating has been achieved in
tion, but not of limitation, an embodiment of this inven 60 the ?rst dip coat and dripping from the patterns has be
tion is shown in the accompanying drawing in which-— come minimized, the stucco is sprinkled onto the wet
Fig. 1 is a ?ow diagram of the process embodying the coating of the cluster while constantly changing the posi
features of this invention starting from the cluster of tion or the cluster substantially uniformly to cover the
wax patterns to the completion of the mold for pouring dip coat with a layer of the stucco while, at the same time,
the metal castings; 65 minimizing flow of the dip coat whereby non-uniformities
Fig. 2 is a perspective elevational view in partial section might otherwise develop. In practice, the stucco particles
of a wax cluster employed in the practice of this invention; will be rained down from above through a screening
Fig. 3 is a perspective view of the cluster shown in Fig. member constantly being fed by a vibratory feeder to re
2 with the castings applied thereon in accordance with move foreign matter from the Alundum particles while
the practice of this invention; 70 the particles are sprinkled over an area to give more
Fig. 4 is a perspective view similar to those of Figs. 2 uniform and complete coverage. The stucco will ad
and 3 of the shell mold after the baking operation to re here to the wet coating of the slurry and will become par
 2,961,701
3 4
tially embedded in the slurry to become integrated with 5-10 or more dip and stucco coats of the type described
the coating formed on the cluster of wax patterns. may be applied in series onto the wax cluster.
If the dip coat is adjusted to enable gelation to take
place within a very short period of time, greater than the Eutectic composition
time required for drainage and stuccoing, the stucco 8000 cc. colloidal silica
cluster need not be set aside for drying. However, it is (Ca0,<6%)
preferred to slow the gelation of the dip coat so that suf (speci?c gravity 1.198)
?cient leeway is available for the desired drainage and 165 pounds zircon
stucco application and to enable correction for de?ciencies (99% through 325 mesh)
which might exist with respect to one or the other. Thus, 10 (65-67% ZnO2, 34-32% S102)
it is desirable to provide for an air dry in the amount of 6250 cc. water
from 10-25 minutes and preferably from 10-15 minutes. 115 grams sodium ?uoride
It will be understood that the time of drying may be ex 18.5 pounds feldspar
tended inde?nitely beyond the preferred minimums de (KZO,<8% )
scribed without harm to the structure. 15 ( CaO,<6% )
Second dip coat (ZnO,<9% )
The composition of the second dip coat slip is substan
(A1203, 16-19%)
tially the same as the ?rst. In practice, use is usually
(5102, 60-63%)
made of the ?rst dip coat slip. The eutectic coating composition is similar in formula
Application of the slip to 20
provide a second dip coat on the stuccoed cluster is tion and preparation to the previously de?ned dip coat
with the exception of the Feldspar which is added to
achieved in a manner similar to that of the previous ?rst
dip coat. gether with the zircon ?our to the mixture.
Second stucco coat The eutectic coating is applied in a manner quite similar
to the dip coats. The stucco cluster is immersed in the
Stucco combination—Alundum (3-60 mesh with less than 25 slip with relative movement between the slip and cluster
3% through 70 mesh) to achieve more uniform distribution and to eliminate as
After the second dip coat has been suitably drained, the much of the air pockets as possible. The coated cluster
coarser particles of stucco are sprayed over the wet sur is then removed from the slip and the excess eutectic coat
faces of the second dip coat to incorporate the Alundum 30 ing composition is allowed to drip from the cluster while
particles into the coating to form a part of the composite turning the cluster to secure a desired uniform coating on
mass and to lock the coatings into each other. When the surfaces.
suitably covered, the cluster is set aside or hung for a short After the eutectic coating has been suitably drained, it
time to set the binder. is stuccoed as in the additional stucco coats described and
Further dip coat slips 35 then the cluster is allowed to air dry. Suf?cient air dry
ing will take place Within 16 hours at ambient temperature
The composition of the third and additional dip coat and the drying time can be shortened considerably by
slips corresponds to the composition of the ?rst and sec using a dehumidified atmosphere. It is possible under
ond clip coat slips. Use is usually made of the ?rst or suitable controlled conditions completely to dispense with
second clip coat slips which probably have become con 40 the air drying step and proceed almost immediately to
taminated by the presence of coarse particles of Alundum the baking or ?ring operation in the preparation of the
or stucco removed from the cluster during previous dips. mold but it is preferred to make use of a drying and aging
This is because a slip with coarse particles of the type period su?icient, at least, to remove free moisture, when
described would be unsuitable for use as a ?rst dip coat present.
because of the undesirable effect that the coarse particles 45 Firing the cluster
would have on the mold surface and on the casting pro The cluster having the predetermined number of dips
duced within the mold. In commercial practice, where and stucco coats and one or more of the eutectic coats
the dip coat compositions will be consumed at a rela on the surface is subsequently ?red by exposure to a tem
tively rapid rate, the separation as between the ?rst and perature of 1800° F. for from 3-30 minutes, depending
subsequent dip coats is not so important, but it is preferred 50 greatly upon the mass of material which is being sub
to go up the scale rather than down if any changes are jected to the ?ring and baking operation. The cluster is
made.
The third and additional dip coat is achieved in essen
usually suspended with the crucible facing downwardly
in the furnace so that the wax can drain from the mold
tially the same manner as the ?rst and second clip co its
as it is reduced at these temperatures to molten state.
by immersion of the cluster with the ?rst and second 55 The great majority of the wax from the patterns and
stucco coats into the slurry while turning the cluster or
by revolving the drum in which the slurry is contained. parts will be removed by drainage While in the molten
After coating, the cluster is drained while turning to pro st te and the residue which remains in the mold will be
vide a uniform coating of the slip over the entire surface rapidly burned out at the temperature conditions exist
ing.
with the exception of the lip o‘. the crucible. 60 The ?red product can thereafter be set aside to cool.
F urtker stucco cocts The lip will be ground down to provide a ?attened sur
Stucco—tabular alumina face adapted more substantially to conform with the
face plate of an invertible furnace in which the metal is
For the third and additional stucco coats use is prefer reduced to the molten state so that the ?nished mold can
ably made of tabular alumina in the form of coarse par 65 be clamped to the face plate of the furnace to enable the
ticles ground to pass through a 14 mesh sieve and to be metal to be poured directly into the shell mold by inver~
retained on a 20 mesh sieve with less than 10% through a sion. In practice. it is preferred to grind down the lip
50 mesh sieve and less than 1% on a 6 mesh sieve. before the ?ring step.
Application is made as before onto the wet layers of While a shell mold suitable for pouring Will be se
the previous dip coat after proper drainage and distribu 70 cured at the conclusion of the ?ring step used to free
tion. After each coat. the coated wax pattern or c‘uster the shell of the wax patterns, gates and other parts and
of patterns is allowed to dry or set to the gelled stage to mature the ceramic materials making up the shell
prior to the next series of coatings. l‘ gel‘ition occurs mold. some expansions and contractions do take place
almost immediately upon application of the stucco coat. which may result in the formation of small cracks and
the drying step may be dispensed with. Usually from ?ssures. Thus it is preferred, in accordance with the
 3 6
practice of a concept of this invention, to provide for ticles of exfoliated mica, bloated silica, Santocel and the
additional vitri?cation in the outer portion of the mold like. Still further, the rate of cooling to the solidi?ed
and to increase the strength of the mold while at the state can be retarded by placing the poured mold in a
same time sealing the cracks and ?ssures by the applica heated space, such as a furnace, in which the temperature
tion of another eutectic coating to the outer surface of of the atmosphere can be controlled.
the shell mold subsequent to the ?ring operation. This Having previously described the process from the time
builds up an additional concentration of Feldspar and that the wax patterns are assembled in the cluster to the
the like lower melting ceramic which is barred by the pouring of the molds, detailed description will now be
previous layer from deep penetration of the mold and made of concepts embodying additional features of this
thus remains more concentrated on the surface where it l0 invention.
can provide vitri?cation and where it can heat seal the The dip coat compositions ma)r deviate quite Widely
pores or cracks in the mold. from the compositions set forth in the foregoing descrip
The post-?red coat corresponds to the eutectic coat tion since they may correspond to the formulations con
ing and application is the same as in the application of ventionally employed as a base for the application of
the eutectic coat prior to the ?ring operation. When a 15 stucco coats in conventional investment casting processes
post-?re coat is applied, the coated shell is set aside to as de?ned in the aforementioned patents.
dry and the ceramic is matured as an incidence to pre The improvements embodying the concepts of this in
heating of the mold to the temperature desired for vention ?nd their support, however, in a combination
pouring. For this purpose, the mold is usually pre which makes use of zircon ?our as a ?ller in the dip coat
heated to a temperature within the range of l600-2200° 20 compositions by way of displacement of ?int or silica
F. and preferably to a temperature within the range of ?our which is usually employed. It has been found that
17004900“ F. and is then clamped to the furnace for silica ?our is subject to large inversions during tempera
turning over to pour the metal into the heated mold. ture change between room temperature and 2000° F.
One of the novel characteristics of a mold prepared whereby large contractions and expansions are caused to
in accordance with the practice of this invention resides 25 take place which introduce stresses within the mold that
in the ability to preheat the mold for an extended period cause deterioration or destruction. With silica, as with
of time, as for days, at the temperature conditions de other materials, if the inversion stages are traversed
scribed without noticeable effect from the standpoint of quickly, cracks are formed in the mold part through which
“slumping” or the type of vitri?cation which is char cast molten metal can escape. This condition would be
acteristic of systems heretofore employed. 30 highly objectionable in an investment casting, let alone
Pouring a system wherein the mold part is adapted to be clamped
to the furnace for pouring without investment or other
Prior to pouring the mold can be very carefully and protective covering.
completely inspected to eliminate imperfect molds which Both the alumina, used as the stucco, and the zircon
might otherwise produce metal castings incapable of use. 35 used as the ?ller in the dip coating compositions embody
The ability carefully to inspect the molds at this stage, ing features of this invention have been found to be rela
prior to pouring, materially reduces scrap loss by com tively free of these inversion characteristics by compari~
parison with the investment casting process wherein the son with silica flour or silica. The expansion and con
mold cannot be inspected so that any imperfections in the traction characteristics of zircon and of alumina are so
mold will remain hidden until their presence is disclosed low by comparison with other materials which have usu
by the unacceptable castings that are produced. ally been employed, that the materials can be heated up
Molds prepared in accordance with the practice of this rapidly to elevated temperature for maturing the mold
invention are characterized by su?icient strength to en or for preheating the mold without endangering the mold
able use as a shell without investment to be clamped by reason of extreme expansions and contractions. It is
as an investment mold to the furnace for pouring. The 45 for this reason that the wax pattern with the described
mold can be clamped to the furnace without additional stucco coats thereon can be introduced into a furnace
support to pour the molten metal therein as by reversal maintained at a temperature as high as 1800-2200‘ F. to
of the position of the furnace as described in the Oper achieve rapid ‘heat-through of the shell for removal of the
hall Patent 2,806,271. The mold retains its strength un pattern and for proper maturing of the ceramic materials
der room or elevated temperatures so that the metal can 50 within the space of 3-30 minutes. This is to be compared
be poured while the mold is cold but preferably after the with the heating and baking cycle of 14 hours or more
mold has been preheated to elevated temperature, such heretofore required for conventional investment molds.
for example as a temperature of l600‘—2200° P. to Thus the time factor in mold preparation can be greatly
facilitate flow of the metal into innermost regions of the reduced and the output per unit space can be greatly in
mold and to insure the production of suitable castings. 55 creased thereby to conserve on the amount of fuel, equip
After the metal has been poured, the ‘poured mold is ment and space required for the preparation of molds in
removed from the furnace and set aside for solidi?cation accordance with the practice of this invention.
of the metal. Upon proper solidi?cation, the mold can By way of further improvement in the process of mold
be broken up to remove the casting and then the latter preparation secured by the practice of this invention, more
can ‘be processed in the usual manner for separation, 60 rapid heat-through enhances removal of the wax pattern
cleaning, inspection and packaging to provide a ?nished and parts Without endangering the mold. Slow heating
product. of the molds, as‘ necessitated by the conventional invest
In accordance with one of the further concepts of this ment casting process, permits the wax pattern and parts
invention, it has been found that the conformity of the to become heated through before elevated in temperature
castings to the mold and the physical and mechanical 65 to a molten state whereby expansions are caused to take
properties of the casting can be materially improved if, place while the wax pattern and parts are still in a non
instead of allowing the cast mold to cool in the open at ?owable condition and fully con?ned within the invest
mosphere, the cast shell mold is housed within an in ment. Expansion of the wax patterns while still in a solid
sulated container whereby cooling is achieved at a slow 70
i?ed state results in the development of tremendous forces
which often lead to loss in dimension of the mold and
and controlled rate for solidi?cation and cooling of the sometimes to the destruction and deterioration thereof to
poured metal. In the alternative, the cooling rate can provide imperfections which cannot be determined prior
be slowed under controlled conditions by placing the to the removal of the castings from the mold. The more
poured mold in the housing and ?lling the space about rapid heat-through permitted by the concepts embodying
the mold with a ?owable insulating material such as par 75 features of this invention provides for an entirely different
 2,961,751
7 8
operation. The outer portions of the wax pattern and in the face of the coating. These will be ?lled by the
parts are reduced to a molten state prior to heating up cast metal and appear as pimples in the ?nal product.
the interior portions of the wax patterns and parts so that On the other hand, if the stucco is too small, such for
the wax in the outer portions can be eliminated from the example as ?ner than 120 mesh, the stucco fails to
mold prior to heating through the pattern. As a result, develop the mechanical lock desired between the ?rst
space is made available for subsequent expansions which and second dip coats and often leads to spalling. In
take place upon heating up of the patterns and parts to general, the balance between the mesh size of the stucco
minimize the development of destructive forces in the and the thickness of the dip coat can best be determined
mold. by trial and error but it will usually fall within the
While silica can be used, as in conventional dip coating limitations described. The coverage of the dip coat sub
compositions, it has been found that it is possible to make sequent to the ?rst is enhanced if the stucco coat pre
use of much more rapid heating for maturing and pre viously applied is pre-wet as by a wash coat formed of
heating the mold when zircon is employed instead of silica the dip coat composition markedly reduced in viscosity.
as the ?ller in these compositions. This enables better Considerable bene?t is derived when a pre-wet is em
control over the casting process when used for high tem 15 ployed in advance of the use of a dip coat of higher
perature alloys. Silica also comprises a basic refractory viscosity than employed in previous dip coats.
which fuses within the temperature range of 3100-3180” For the second stucco coat, it is desirable to make
F. and which is capable of reaction with the hot metal use of a material of about 50 mesh. Material larger
to develop a slaggy condition that enables silica to be than 35 mesh is too coarse and permits air pockets to
washed from portions of the mold. This leaves an indef 20 form with possible metal break-through. When less
initeness in some portions of the mold and the slagging than 100 mesh, it becomes more difficult to develop the
o? of the silica provides for contamination of the metal desired mechanical interlock between layers. The stucco
casting to produce an undesirable and unacceptable prod for the third and subsequent coats is preferably selected
uct. On the other hand, by using zirconium or zircon of materials within the range of 14-28 mesh. Larger
as the ?ller, temperatures up to 4000-4600° F. can be 25 mesh materials can be employed but it is undesirable
employed before fusion. Reaction conditions for slag to exceed 1/1 inch material. Finer materials can be em
ging off are substantially avoided thereby to maintain ployed consistent with the desire to develop an adequate
dimensional stability and mold contour for the produe— mechanical lock. Instead of Alundum, use as a stucco
tion of good castings, even with high temperature alloys. coat can be made of zircon, sillimanite, mullite, vycor
The combination of conditions of zircon ?ller and high 30 glass. thoria, chromite, magnesia and the like materials
temperatures for more rapid maturing of the mold and having good heat-shock, good refractory characteristics,
for casting high temperature alloys are thus employed to low expansion rate and expansion and contraction char
improve the casting process and the preparation of molds acteristics close to those of the ?ller in the dip coat.
therefor. An important concept of this invention resides in the
Instead of zircon, use can be made of ?nely divided 35 means for providing an outer portion in the built-up
particles of ?ours of alumina, titania, stabilized zircon, shell which is capable of insipient fusion or a stage of
fused quartz, thoria, chromite, sillimanite, mullite, mag vitri?cation at temperatures below the vitri?cation tem
nesia, vycor glass, or the like materials having similar perature of the zircon to provide a skin barrier which
inversion characteristics, good heat-shock properties, high has maturity at lower temperature to form a protective
fusion temperature and relatively low expansion charac 40 cover; heal any fractures or cracks which might develop
teristics at elevated temperatures within the range from in the mold during burning out, preheating and particu
room to 2200" F. It will be understood that the binder larly during pouring of the metal, and markedly to
component of the slip may comprise other conventional strengthen the mold to impart mass integrity which en
binders employed in the preparation of the stucco coats ables use of the shell mold without support for casting
on wax patterns or patterns formed of other low melting 45 molten metal therein, with or without the accompaniment
materials employed in investment castings. When such of pressure.
other binder systems are employed, the zircon and the Brie?y described, the characteristics are achieved by
like ?ller can be incorporated in the amounts previously the formulation of an outer coating of the shell mold
described. with Feldspar presented as a component of the ?ller in
With reference to the dip coat slips, it is desirable to 50 the dip coat. Feldspar vitri?es at a temperature start
make use of a fresh slip for the ?rst dip coat since the ing at about 1000° F. and continues on up to a tempera
initial coating is more critical from the standpoint of ture of about 2200° F. Thus the Feldspar vitri?es alone
thickness and character and better controls are available and in combination with the siliceous materials present
in a newly prepared batch. As a ?rst dip coat, it is at the temperature conditions existing during ?ring and
desirable to provide for a thickness on the patterns which 55 preheating to form a eutectic ceramic which is capable
will enable the stucco to enter into the coating without of sealing the pores and cracks which are present or
penetration all the way through to the inner face of the which otherwise form in the mold shell during ?ring,
mold. If the coating is too thick, the extra layer at the preheating or metal pouring.
inner face will not be mechanically held strong enough As a result of the sealing characteristics made avail
to prevent separation from the rest of the mold so that 60 able by the Feldspar in the outer eutectic coat or coats,
the inner layer of the dip coat can be pulled off under the cracks are blocked before metal can flow there
certain conditions to cause spalling. If the dip coat ?lm through during pouring with the result that the mold
is too thin, the stucco will penetrate through to cause the is saved, metal is saved and a higher yield of product is
slip to ?ow into the crevices between the stucco particles secured from the total of the metal poured. Scrap loss
and leave a rough inner face against which the metal is 65 has been reduced from values as high as 40-50 percent
cast. Thus it is desirable to provide for a balance between to an average of a few percent by the employment of
?lm thickness and stucco. the concepts forming the subject matter of this invention.
For this purpose, it has been found best to provide The eutectic operates as a ceramic flux to secure the
for a ?lm thickness in the ?rst stucco coat of about
5-10 mils with about 20 mils as a maximum and about 70
particles of stucco in the mold markedly to strengthen
3-4 mils as a minimum and it is desirable to make use the mold shell to the extent that the mold can be clamped
of a stucco in a ?rst stucco coat of about 60-80 mesh on to the furnace for pouring the metal without invest
material. If the mesh size of the stucco is considerably ment or otherwise supporting the mold and to the extent
larger, capillary actions developed will operate to bleed that it is capable of withstanding normal forces existing
moisture from the dip coat composition and leave voids 75 in normal handling and clamping as well as internal
 £2,961,751
'10
forces of the liquid, heat and pressures which might be desired sequence in the elimination of the wax pattern
employed in combination with metal pouring. and parts when ?ring at temperatures below 1600" F.
It is desirable to make use of an amount of Feldspar Within the temperature range of 1600-2200° F. time is
capable of imparting the desired strength characteristics not an important factor. Very often 3 minutes is suffi
described but it is undesirable to make use of such con cient at these temperatures but it is preferred to heat
centration as will lead to excessive diffusion into the for about 30 minutes. Heating for more than 30 minutes
mold or will cause the development of hot tears. Feld at the temperatures described is not harmful. Above
spar in amount less than 0.05 part per one part by 2200° F. the strength properties of the shell mold will
weight of zircon or other ?ller in the dip coat has been be increased but reactions are possible which might cause
found to be insu?icient to impart the desired strength excessive shrinkage in the shell mold.
characteristics. When the amount of Feldspar exceeds In general, the thickness of the dip coats will increase
0.25 part per one part by weight of zircon or other from the inside out because of the increased porosity
?ller, the mold becomes so strong that it will lead to provided by the stucco. However, on the average, a
hot tears in operation and excessive diffusion into the shell formed of about ?ve dip coats and an equal num
mold may occur. It is preferred to make use of the 15 ber of stucco coats will have a thickness of about ‘A
Feldspar in an amount within the range of 0.08-0.15 inch and will be made up of about 60 percent by weight
part by weight of the Feldspar to one part by weight of dip coat solids, 35 percent by weight coarse stucco of
the zircon or other ?ller in the dip coat or about 8~l5 14—28 mesh, about 2 percent by weight of 20 mesh stucco
percent by weight of the ceramic solids of the dip coat. from the ?rst stucco coat, about 3 percent by weight 54
In operation, the Feldspar has a tendency progressively 20 mesh stucco from the second stucco coat, Feldspar will
to diffuse inwardly during ?ring. Since it is undesirable form about .5-1 percent by weight of the shell and it
to have the Feldspar penetrate into the inner surfaces of will be located almost exclusively in the outer layer or
the mold, the time and temperature for heating should layers before ?ring.
be balanced with the amount of Feldspar to enable After the eutectic coat, it is desirable to dry the mold
eutectic formation without complete penetration. Too 25 for about 8-15 hours before ?ring. After ?ring, the
much Feldspar, that is above the amount previously shell mold may be processed by grinding down the lip
indicated, would enable progressive reaction to penetrate to provide a ?at surface for clamping to the top plate
farther into the shell mold where undesirable conditions of the melting furnace to achieve a sealing relahonship
can be developed since the Feldspar is capable of re therebetween which enables the shell mold to be clamped
action with the metal while in the molten state. Further 30 to the furnace whereby the furnace is subsequently in
it can form products which do not have the desired verted for pouring. After ?ring, it is preferred to also
heat-shock resistance and thus the formation of such provide an additional eutectic coat on the outer surface
products should be limited to outer portions of the shell of the shell to provide increased amounts of vitri?cat.on
mold. Thus it is desirable to limit the addition of or insipient fusion and to provide additional Feldspar
Feldspar to dip coat compositions forming the outer coat 35 for sealing the cracks and pores formed during the sub
ings or the outer coating of the shell mold. While de sequent preheating operation and metal pouring opera
scription has been made to the use of the outer coating tion. As previously pointed out, the shell mold formed
as the eutectic coating containing the Feldspar, it will be in accordance with the practice of this invention bears
apparent that the eutectic coating can constitute one of sufficient strength to enable it to be clamped directly onto
the intermediate dip coats, which may or may not be 40 the furnace for metal pouring as distinguished from the
stuccoed, on the condition that the eutectic coat is spaced necessity to invest the shell within a ceramic support as
at least two coats and preferably ?ve or more coats from in previous investment casting processes. The shell mold
the face of the shell mold. can be critically inspected prior to preheating and sub
Practice of the concept described by modi?cation of sequent to preheating and prior to clamping the shell onto
the dip coat to embody Feldspar in an outer coating 45 the melting furnace to discard defective shell molds and
provides a shell mold having an inner face which is still thereby avoid the waste of time and material in pouring
highly refractory and incapable of reaction with the unsuitable and unacceptable castings. Preheating can
molten metal and an outer coat which functions as a be carried out in the usual preheating furnace to rajse
lower maturing coat which is capable of automatically the temperature of the mold to a desired high temperature
sealing up pores and cracks that may form while at for metal casting thereby to insure complete flow of
the same time wetting the particles with the eutectic the metal into the innermost recesses of the mold with
type of binder markedly to increase the strength and the result that acceptable castings of a uniform high
toughness of the shell mold while, at the same time, quality can consistently be secured.
reducing its heating time and temperature to maturity. The cast metal shell can be removed from the furnace
By varying the composition of the eutectic coating, 55 and set aside for cooling to solfdify the metal but, as
temperature for maturing can be varied from 1000—2300° previously pointed out, castings having improved physical
F. Though not equivalent, use can be made of iron and mechanical properties and improved formation can
oxide, borax or stannous chloride and the like low be secured, when, in accordance with the practice of
temperature vitri?able inorganic materials instead of this invention, the poured shell mold is con?ned within
Feldspar. The eutectic coat composition will generally 60 a thermal insulating barrier during the cooling operation
be used at a lower viscosity than the conventional dip to solidify the metal or placed within a con?ned space
coats for stuccoing. In the composition described, the subsequently ?lled with vermiculite or other particulate
Feldspar acts differently than borax in that it is capable thermal insulat ng material. Instead, the poured molds
of greater stability in suspension wlthout upsetting the can be allowed to solidify in a furnace heated to elevated
balance as compared to borax. temperature to slow the solidi?cation or the metal can
In the ?ring operation to mature the ceramic mate be poured into a mold while housed within the furnace
rials and to effect removal of the wax patterns from the in which it is preheated or in another furnace.
shell mold, it is desirable to avoid the use of temperatures It will be apparent from the foregoing detailed de
much in excess of 2200° F. because otherwise the mate~ scription that considerable advantages are capable of
rials will tend to form a glassy phase which adversely being derived by a metal casting process embodying
affects the mold. The minimum temperature is that tem features of this invention:
perature suffic'ent to activate the binder. For borate, (1) It is possible to reduce the ?ring operation from
temperatures as low as 500° F. could be used but, in the 16 or more hours characteristic of conventional in
general, it is preferred to make use of a temperature in vestment casting processes to as little as from 3-30 min
excess of 1600” F. because it is difficult to effect the 75 Utes.
 2,961,761
11 12
(2) The materials employed in the preparation of the ceramic material in the outer portion of the composite
shell mold for casting can be reduced from a representa coating whereby the lower maturing ceramic material in
tive value of $2.50 per cluster to as little as 90 cents the outer portion of the coating reaches a state of in
for an equivalent cluster. The foregoing applies to the cipient fusion during ?ring of the mold to an elevated
mold materials only since the investment can be com temperature above the incipient fusion temperature of
pletely eliminated. the lower maturing ceramic material prior to metal pour
(3) The increased strength and mass integrity of the ing to seal the cracks and pores formed in the mold to
shell mold formed in accordance with the practice of this prevent the ?ow of molten material therethrough and
invention permits the shell mold to be clamped directly to strengthen the mold to enable use without additional
to the furnace for pouring as distinguished from the 10 support during metal pouring.
necessity to invest the shell mold in conventional invest 2. The metal casting process as claimed in claim 1 in
ment casting processes. which the heat step for removal of the heat disposable
(4) The ability to clamp the shell mold directly to the patterns and maturing the mold is carried out by expos
furnace for pouring coupled with the high strength char ing the coated patterns to a temperature within the range
acteristics of the shell mold at the elevated temperature 15 of 1600-2200° F.
conditions existing permits the use of pressure in the 3. The metal casting process as claimed in claim 1 in
metal casting process to achieve more rapid and com which the ceramic material in the dip coats comprises a
plete ?lling of the mold as distinguished from the in material having a high melting point range above 3000'
ability to make use of pressure in other shell molding F. and a low inversion factor to enable heating of the
processes. 20 mold shell to higher temperatures in wax removal, pre
(5) Because of the more refractory materials and their heating and pouring and to enable rapid temperature
combination in a shell mold produced in accordance with change to take place in the mold without excessive ex
the practice of this invention, it is possible to pour metal pansions and contractions.
at higher temperatures which leads to the further possi 4. The metal casting process as claimed in claim 2 in
bility of pouring a greater variety of metals in the metal 25 which the material is selected from the group consisting
casting process. In addition, the ability to make use of of zircon, alumina, titania, stabilized zircon, fused
a higher metal pouring temperature is directly instru quartz, thoria, chromite, sillimanite, mullite, magnesia
mental in achieving more complete flow of the metal in and vycor glass in a ?nely divided form.
the mold to achieve more uniform and better castings. 5. The metal casting process as claimed in claim 1 in
(6) Because of the good thermal characteristics of the 30 which the ceramic material of lower maturity is incor
materials making up the shell mold, a wider range of porated as a dip coat applied subsequent to at least three
temperatures is possible to enable pouring of the metal previous dip coats and before ?ring.
into shell molds both hot or cold. 6. The process as claimed in claim 5 which includes
(7) The ability completely to inspect the shell mold the step of air drying the structure subsequent to the
in advance of metal pouring is instrumental in reducing 35 application of the coating of low maturing material and
the scrap loss of the metal casting process by compari before heat treatment to mature the mold.
son with prior investment casting processes wherein the 7. The method as claimed in claim 5 which includes
mold is incapable of being inspected prior to metal pour the additional step of applying a second coat of the low
ing. Thus it is possible to eliminate defective molds maturity material subsequent to the ?ring for maturity
before pouring metal castings therein to produce defec 40 and which includes the step of preheating the mold in
tive castings thereby greatly to increase the yield of advance of the metal pouring step to cause incipient
acceptable products. fusion of the applied low maturity material.
(8) By reason of the ability to clamp the shell mold 8. The method as claimed in claim 5 in which the
to the furnace, considerable conservation in heat can be low maturing material comprises \Feldspar in a ?nely
effected by comparison with the transfer process here 45 divided form.
tofore required in pouring the metal from the melting 9. The method as claimed in claim 8 in which the
furnace into a ladle and conveying the ladle to the mold mold shell is preheated to a temperature within the range
for pouring. of 1600-2200° F. prior to metal pouring.
(9) It is possible also to melt the metal in the furnace 10. The method as claimed in claim 1 in which the
under a protective atmosphere and to maintain the de 50 matured shell mold is clamped directly onto an invertible
sired protective atmosphere during the pouring of the metal melting furnace for pouring the metal into a shell
metal into the shell mold when clamped, as previously mold.
described, to the melting furnace. Such protective at 11. The method as claimed in claim 10 which makes
mosphere cannot be maintained where the metal must use of super-atmospheric pressure in pouring the metal
be removed from the melting furnace for transfer by 55 in the clamped mold.
ladles to the mold for pouring. 12. The method as claimed in claim 10 which makes
It will be apparent from the foregoing that we have use of an atmosphere inert to the molten metal during
provided an improved method and materials for the melting of the metal and pouring of the molten metal
production of metal castings. It will be understood that into the shell mold.
changes may be made in the details of materials, their 60 13. The method as claimed in claim 1 which includes
formulations, their applications and in the operations the step of controlling the cooling rate to slow the so
without departing from the spirit of the invention, espe lidi?cation of the metal.
cially as de?ned in the following claims. 14. The method as claimed in claim 13 in which the
We claim: step of slowing the solidi?cation comprises surrounding
1. In a metal casting process wherein a plurality of 65
stucco and dip coats of ?nely divided ceramic material the mold with thermal insulating material in particulate
are built up onto the surface of a pattern of material form.
which is disposable at elevated temperature and which 15. The method as claimed in claim 13 in which the
is subsequently ?red to dispose of the pattern and to step of slowing the solidi?cation of the metal comprises
mature the ceramic materials in the coating and wherein 70 housing the mold Within a thermally ‘insulated space im
a metal in a molten state is poured into the matured mediately after pouring.
mold to produce metal castings, the improvement which 16. A shell mold produced by the method of claim 1.
comprises incorporating a ceramic material having a 17. A shell mold produced by the method of claim 8.
lower maturing temperature than the other materials
making up the plural coatings with the lower maturing 75 (References on following page)
 2,961,751
14
References Cited in the ?le of this patent 2,790,219 Kohl et a1. ___________ __ Apr. 30, 1957
UNITED STATES PATENTS 2,806,269 Dunlop ______________ __. Sept. 17, 1957
2,806,270 Shaul ________________ __ Sept. 17, 1957
1,370,276 Buckman et a1. ________ __ Mar. 1, 1921 2,806,271 Operhall _____________ __ Sept. 17, 1957
2,154,069 Fessler et a1. _________ __ Apr. 11, 1939 5 2,815,552 Turnbull _____________ __ Dec. 10, 1957
2,388,299 Thielernann ___________ _- Nov. 6, 1945
OTHER REFERENCES
2,441,695 Feagin et a1 ___________ __ May 18, 1948
2,507,867 Pomes _______________ __ May 16, 1950 Hackh’s Chemical Dictionary, 3rd edition, 1953, page
2,680,890 Moore et a1 ___________ __ June 15, 1954 180.