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Shell Permeability Presentation
Shell Permeability Presentation
Moderated by
Julie Markee - Key Process Innovations
WHAT IS PERMEABILITY?
JM
WHY DO WE MEASURE PERMEABILITY ?
• Troubleshooting Tool
• Comparison between shell systems
• Comparison between waxes
JM
HOW DO WE MEASURE PERMEABILITY?
JM
HOW DO WE MEASURE PERMEABILITY?
JM
MEET THE PANEL
Craig Lanham – Retired from 3M after 38 years in the
investment casting industry
Thad Nykiel – A 38 year veteran of the investment casting
industry currently serving as Process Engineering Manager
at Bescast
Nip Singh – Been in the industry for over 40 years and is
passionate about reducing variability in the process
Taylor Thornhill – Metallurgical Engineer with O’Fallon
Castings. Two time recipient of the ICI National Intern
Scholarship
JM
A LITTLE HISTORY
CL
BESC AST, INC .
TN
BESCAST PERMEABILITY TEST STATION
TN
2015 MONTHLY DEWAX CRACK (%)
1000
900
886
819
800
697
Permeability (x10-12)
700
600
500
400
300
100
200
300
400
500
600
700
800
900
0
5/26 #1 795
#2 783
#3 610
#4 689
6/7 #1 610
#2 734
#3 749
#4 723
6/14 #1 518
#2 546
#3 531
#4 507
6/21 #1 430
#2 506
#3 471
#4 425
7/20 #1 460
#2 437
#3 419
#4 474
415
8/26 #1 670
#2 636
#3 565
#4 629
TN
DEWAX CRACK IMPROVEMENT
CL
CASE STUDY #1
NS
CASE STUDY #2
• Client changed manual dipping to Robot dipping
• Shell started cracking with the same number of dips
• Client added many coats and others “band aids”
• Green permeability showed real issue was sanding method change
• Introduced a FB system in for sanding
• Back to almost original condition and no need for extensive FAI
NS
CASE STUDY #3
NS
A Study of Hot Shell Permeability:
Identifying Sources of Variation
Taylor Thornhill
O’Fallon Castings
O’FALLON OVERVIEW
TT
RAISING THE FLAG
Despite the efforts taken toward process control, we were seeing day-to-day
variations in casting quality using digital x-ray.
TT
THERE MUST BE VARIATION IN OUR PROCESS...
Melt Quality
Mold
Properties
Degassing/ Metal
Filtration Chemistry
TT
We believed to have extensive shell knowledge and
reproducibility…
JM
RESOURCES / REFERENCES – PRIMARY
• Ferg, Brian J., 1979, “Influence of Mold and Wax on Dewaxabilty”, Investment
Casting Institute, 27th Annual Meeting.
• Lang, W., Learmonth, D., McCallum, R., 1988, “Hot Permeability of Shell
Moulds: Its Measurement and Place in Process Technology”, Investment
Casting Institute, 36th Annual Meeting.
• Hendricks, Michael J., Engelhardt, Donald R., 1990, “Ceramic Shell
Permeability”, Investment Casting Institute, 38th Annual Meeting
• Roberts, William O., Watson, Lewis D., 1998, “A Green Permeability Test”,
Investment Casting Institute, 46th Technical Conference & Expo.
• Snow, Jerry D., Scott, David H., Snyder, Bill S., 2002, “Permeable Prime Coats:
Effect On Dewax Shell Cracking”, Investment Casting Institute, 50th Technical
Conference & Expo.
• Snyder, Bill S., Scott, David H., Snow, Jerry D., 2003, “A New Combination
Shell Strength and Permeability Test”, Investment Casting Institute, 51st
Technical Conference & Expo.
RESOURCES / REFERENCES – PRIMARY
• Jones, S., Yuan, C., Jolly, M. R., 2003, “Fluid Bed and Rain Fall Sanded Shells – An
Investigation into Fundamental Structural and Mechanical Property
Differences”, Investment Casting Institute, 51st Technical Conference & Expo.
• Branscomb, Tom, 2004, “A New Method of Measuring Green and Fired
Permeability of Investment Casting Shells”, Investment Casting Institute, 52nd
Technical Conference & Equipment Expo.
• Wolfe, Casey M., Dickerson, Kay L., Hendricks, Michael J., 2009, “A New Look
at Shell Permeability and the Factors That Impact It”, Investment Casting
Institute, 56th Technical Conference & Expo.
RESOURCES / REFERENCES - ANCILLARY
• Whitehouse, C., Snyder, B., 2007, “Slurry Mixing Methods and their Effect
upon Slurry Viscosity, Particle Size and Shell Properties”, Investment Casting
Institute, 55th Technical Conference & Expo.
• Whitehouse, Chris and Dahlin, Barry, 2008, “Effects of Wax Viscosity and Shell
Permeability on Shell Cracking”, Investment Casting Institute, 56th Technical
Conference & Expo.
• Oles, Mark, 2009, “A Statistical Approach to Improving Dewax Performance”,
Investment Casting Institute, 57th Technical Conference & Expo.
• Kline, D.M., Lekakh, S.N., Richards, V.L., 2010, “Improving Investment Casting
Mold Permeability Using Graphite Particles”, American Foundry Society,
Schaumburg, IL.