The article presents an analysis of the applicability of the Replicast CS process as an alternative to the investment casting process, considered in terms of the dimensional accuracy of castings. Ceramic shell moulds were based on the Ekosil binder and a wide range of ceramic materials, such as crystalline quartz, fused silica, aluminosilicates and zirconium silicate. The linear dimensions were measured with a Zeiss UMC 550 machine that allowed reducing to minimum the measurement uncertainty.
Extremely intense development of civilization requires from foundry casting technologies very high quality and not expensive castings. In the foundries, there are many treatments that allow increasing of the final properties of produced castings such as refining, modification, heat treatment, etc. One of the methods of increasing the quality of the casting by removing inclusions from the liquid alloy is filtration. The use of ceramic-carbon foam filters in filtration process is still analysed phenomenon that allows improving the final properties of castings. A modern method of research, testing and synthesis of innovative chemical compositions allows improving the properties of such filters. In the paper the evaluation of application properties of developed ceramic-carbon bonded foam filters is presented. The quality of the foam filters is evaluated by Computer Tomography and foundry trials in pouring of liquid metal in test molds. Additionally computer simulations were made to visualize the flow characteristics in the foam filter. The analysed filters are the result of the research work of Foundry Research Institute and the Institute of Ceramics and Building Materials, Refractory Materials Department in Gliwice.
Trials of cast steel filtration using two types of newly-developed foam filters in which carbon was the phase binding ceramic particles have been conducted. In one of the filters the source of carbon was flake graphite and coal-tar pitch, while in the other one graphite was replaced by a cheaper carbon precursor. The newly-developed filters are fired at 1000o C, i.e. at a much lower temperature than the currently applied ZrO2-based filters. During filtration trials the filters were subjected to the attack of a flowing metal stream having a temperature of 1650°C for 30 seconds. Characteristic of the filters’ properties before and after the filtration trial were done. It was found, that the surface reaction of the filter walls with molten metal, which resulted in local changes of the microstructure and phase composition, did not affect on expected filter lifetime and filtration did not cause secondary contamination of cast steel.