CHARACTERIZATION OF ZIRCON-BASED
SLURRIES FOR INVESTMENT CASTING
J. Bundy and S. Viswanathan
Department of Metallurgical and Materials Engineering, The University of Alabama, Tuscaloosa, AL, USA
Copyright 2008 American Foundry Society
Abstract
Zircon is used in either the prime slurry and/or stucco in
a majority of investment casting foundries. The current
shortage in the supply of zircon, together with its rising price,
means that many investment casting foundries will be forced
to use alternate materials, or cut back on production. It would
be of great benefit to the industry if functional alternatives
to zircon could be identified and produced at comparable
cost. This paper contains a baseline evaluation of a zircon
prime slurry, including tests and quality metrics to quantify
Introduction
Zircon is used in either the prime slurry and/or stucco in
a majority of investment casting foundries. Zircon is an
excellent refractory for use in investment casting due to its
round shape and high density which improves flowability
and drainability, its refractoriness which provides low
reactivity with molten metals, a thermal expansion less than
a third that of silica that improves dimensional stability,
and a high thermal conductivity which increases thermal
shock resistance. The high refractoriness allows the use
of finer particles that result in improved surface finish.
The high thermal conductivity and density also increases
its chilling power, which may be partly responsible for
improved surface finish and low reactivity.
The fluctuation in zircon availability, along with its
increasing price due to strong market demand, means that
many investment casting facilities are currently looking
for alternative materials. In order to identify and compare
possible alternatives to zircon, the performance of zircon
must itself be characterized and quantified. In an attempt to
characterize the behavior of zircon prime slurry, a number
of tests were performed. This paper presents the results of
the characterization of baseline zircon slurry.
Zircon Use and Replacement
Almost all foundries use zircon in their prime coat. It has
been estimated that 20% of investment casting foundries
use 100% zircon flour face-coats, 20% use all fused silica,
20% a blend of fused silica and zircon (usually 50% by
International Journal of Metalcasting/Winter 09
its behavior. Specifically, the following measurements were
conducted on a set of six identical zircon prime slurries:
viscosity, bulk density, pH, temperature, wet film thickness,
prime coat bubble count, and plate retention. These quality
metrics and other tests could be used to assess/benchmark
potential zircon alternatives, and evaluate their performance
compared to zircon.
Keywords: zircon, slurry, investment casting, viscosity,
stucco.
volume or 67% zircon by weight, since zircon has twice the
density of fused silica), 20% use 100% alumina (typically,
in the aerospace industry), and the rest use other flours
including alumina-silicates, yttria, and zirconia.1,2 The
most common mesh sizes of zircon are 200, 325, 400,
and 600 mesh, or blends of these sizes, with the optimum
mesh size selected based on a balance of permeability and
surface finish. It has been postulated that as most foundries
tumble blast their parts with media that is coarser than 200-
mesh flour, the use of very fine prime flour is unwarranted.
In addition, coarse flour allows the wax to more easily
penetrate the shell during dewax, reducing the likelihood
of shell cracking.1
Whitehouse et al.1 conducted tests using five prime stucco
materials, four fused silica/zircon prime flour blends,
four alloys, four prime slurry viscosities and four metal
pour temperatures. They concluded that all stuccos tested
could be used if the prime slurry viscosity was optimized.
Guerra3 tested a 60% alumina alumina-silicate as a
direct replacement for zircon sand in the prime coat. The
proprietary alumina-silicate material had a specific gravity
of 2.8 (versus 4.5 for zircon), and a very similar mesh
distribution and thermal expansion as zircon. The alumina-
silicate material has a very similar modulus of rupture
(MOR) and slightly lower permeability compared to zircon.
The chemical compatibility and reactivity of the alumina-
silicate with various alloys were not tested. A recent survey
of zircon use in the investment casting industry sponsored
by the ICI4 provides more up-to-date data on zircon use, the
reasons for zircon use, and potential replacements that are
being considered.
27
Slurry Preparation and Characteristics
The quality of the ceramic shell depends on the slurry and
the process by which the shell is built.5 Consequently,
the goal of slurry preparation should be to produce stable
slurries that meet a given set of slurry parameters. To be
considered stable, slurries must be well mixed and their
viscosity must be stable. Viscosity is initially high when
slurries are mixed; however, as mixing continues and
the refractory material is wetted and air is released, the
viscosity decreases and asymptotically approaches a stable
value. Finer particles wet in more quickly during mixing.6
The main factors that impact the stabilization time of
slurries are:5
a) The mixing equipment
b) The amount and type of additions to the slurry, and
c) The procedures used to make up the slurry.
The type and content of refractory materials in slurries
affects the time required for a slurry to stabilize.5 Primary
slurries that are typically higher in refractory content and use
finer flours will likely take longer to stabilize than backup
slurries. Refractory density may also play a part in the time
to stabilize as lower density refractories may wet out slower.5
It is suggested that when mixing refractories of differing
densities, the lowest density refractory should be added first.5
Refractory morphology affects slurry rheology, since grain
shape defines the surface area to volume ratio. A change
in particle distribution will change slurry rheology. Some
refractories can also be porous.6 Levels of silica, moisture,
solids, and polymers are also among the key factors that can
affect slurry performance. All of the factors, however, are
very difficult to analyze once a slurry has been prepared.
Therefore, proper measuring and mixing techniques are
crucial during the slurry preparation stage.
Slurry Ingredients
Typical ingredients in an investment casting slurry include:
colloidal silica, water and/or polymers, wetting agents,
anti-foaming agents, and refractory flours. All of these
ingredients play an important role in the behavior of the
slurry and the resulting properties of the shell. Typical slurry
characterization in investment foundries includes silica level,
pH, polymer content, moisture content, bacterial content,
solids loading, and viscosity.7
Colloidal Silica: Typically, there are two grades of colloidal
silica used in the investment casting industry. One grade of
colloidal silica has an average particle size of 8 nm and is
classified as small particle, while the other grade has an
average particle size of 12 nm and is classified as large
particle. The large particle colloidal silica is considered to
be better for primary coats due to its lower surface area, and
consequent lower reactivity and longer slurry life.7
28
Polymers: Polymers are used in both primary and backup
slurries due to their many benefits. Most polymers used are
latex polymers, which are aqueous dispersions of polymer
particles that have been stabilized to stay in suspension. It
is important that the latex be compatible not only with the
colloidal silica but also with the refractory flour, wetting
agent and antifoam.7 Polymers provide the following
benefits:
v Reduce or eliminate buckle, lifting and cracking on
the primary coat
v Improve adhesion of primary coat to wax pattern
v Increase green strength and elasticity
v Improve stucco adhesion
v Improve slurry rheology and draining, and
v Enable faster processing of shells due to lower set-
up times
v Improve permeability of the shell by increasing the
amount of open porosity
Refractory Flours: Commonly used refractory flours
include zircon, fused silica, alumina, and alumina-silicates
of varying Al2O3 content.7,8 Zirconia and yttria are used in
specialized applications. Flour particle sizes range from
-200 to -400 mesh (74 to 37 μm) for the primary slurry,
and -120 to -325 mesh (125 to 44 μm) for backup slurries.8
Zircon has a high specific gravity, in the range of 4.6-4.7,
and smooth, round edges that allow particles of zircon to
be closely packed. The high density of zircon flour results
in creamy, smooth-flowing slurries. However, due to its
density (twice as dense as fused silica), a much higher
weight of zircon is required over other commonly used
refractories.
Wetting Agents: Wetting agents are used in primary
slurries to lower their surface tension. Surfactants should be
compatible with the binder system and have low foaming
characteristics. They should be either nonionic or anionic.
One of the most commonly used surfactants is Victawet 12,
which is a nonionic, phosphate ester type wetting agent.
Typically only about 0.5% of the surfactant is required to
properly wet most waxes and promote primary coat slurry
adhesion. An over-addition of surfactants can shorten
slurry life.7
Antifoaming Agents: Antifoaming agents are used in
both primary and backup slurries to prevent foaming and
eliminate any foam that is present. The most commonly
used antifoaming agents are silicone emulsions, which
are diluted with water prior to use. Antifoaming agents
should be either nonionic or anionic in nature and be
fully compatible with the binder system. The lowest
concentration necessary to control foam should be used
which is around 0.1 wt%.7
International Journal of Metalcasting/Winter 09
Slurry Characterization and Control
Several slurry parameters can affect the properties of the
ceramic shell. These include: silica level, pH, polymer
level, solids loading, refractory type and size, and viscosity.
Evaluation of these elements is very difficult once a slurry has
been prepared, and proper measuring and mixing techniques
are crucial during the slurry preparation stage.
Silica Level: Colloidal silica consists of a stable dispersion
of amorphous silica particles in water. The silica particle
sizes are usually less than 100 nm; colloidal silica used in
investment casting usually consists of particle sizes of 8 to
12 nm. The particles remain suspended due to their surface
charges, which cause them to repel each other. When the
particles of colloidal silica agglomerate (gel), the stability
of the suspension is damaged. Agglomeration is favored as
the concentration of binder solids in the slurry increases.
Consequently, the concentration of the binder is important
to the quality of slurry. As the elevation of binder solids
may be caused by evaporation of water from the slurry
during normal use, the binder solids concentration should be
adjusted back into specification with a distilled or deionized
water addition. However, any damage that has occurred is
usually irreversible.5
pH: The pH of slurries affects the life and quality of the
slurry, since a lowering of the pH reduces the repulsive
forces that keep the colloidal particles apart. This may cause
the particles to collide and gel. In general, as the pH of a
slurry approaches its minimum or maximum recommended
limits, the slurry is at a greater risk of gelling. Refractory
materials, waxes, and water may all have components that
reduce the pH of slurries. Microbe growth also reduces the
pH of slurries. Microbes may be controlled with additions of
biocides, while the choice of waxes and refractory materials
may not be as easily controlled. The pH of slurries may be
increased through additions of diluted ammonium hydroxide
and triethanolamine.5
Electrolytes: Electrolytes are ions that are dissolved in the
binder and can disturb the surface charges on the colloidal
particles. Sources of electrolytes include refractory materials,
waxes, addition of non-deionized water, introduction of
pattern cleaners into the slurry, and even operators. Some ions
may actually bridge between particles causing rapid gelling
of the binder. The electrolyte content of the binder cannot be
reduced. Again, the damage to the binder is irreversible.5
Temperature: Temperature affects the solubility of
electrolytes from refractory materials, the evaporation rate of
water, and microbe growth. Consequently, the temperature of
the slurry should be checked periodically and maintained as
close to the ambient as possible.5 A slurry becomes unstable
as its temperature rises and begins to dry out faster. This can
lead to defects in the casting, with inclusions and runouts
being the most common.
International Journal of Metalcasting/Winter 09
Viscosity: Slurry viscosity is influenced by the type and size
of refractory flour used, total solids loading in the slurry,
and to a lesser extent by the type of colloidal silica and/or
polymer used7. There are wide differences in slurry viscosity
as used in industry, ranging from as low as 15 s in a #4 Zahn
cup to as high as 60 s using a #5 Zahn cup.5
Tests and Quality Metrics
Tests for monitoring the refractory flour, slurry quality and
ceramic shell quality include.1-3, 5
v Flour properties–particle density, bulk or tap
density, particle morphology, particle size
distribution, and thermal expansion
v Slurry parameters–binder solids, pH, gel test,
viscosity (Zahn cup), temperature, and density
v Slurry behavior–Slurry index measurements
(viscosity, etc.) and correlation to slurry behavior
(flow, drainability, film thickness, etc.), Plate test
(ICI Test Procedure 720-79)
v Shell properties, including
a. Surface roughness, thermal conductivity,
thermal expansion and sintering/shrinkage
behavior, and chemical reactivity
b. Permeability
c. Shell Strength– Green-Hot-Fired MOR and
creep
Viscosity: The viscosity of a slurry is a measurement of
the flow characteristics of the slurry, and is one of the most
widely used control tests in industry. Viscosity control is
crucial in the production of consistent prime and backup
coats. In the investment casting industry, viscosity is
measured using a Zahn flow cup. The measurement is
reported as the time elapsed for the cup volume to flow
through a hole in the bottom of the cup. The end point of
the test must be chosen so that it is consistent from test
to test.5
Gel Test: The twenty-four hour gel test is used to
determine the stability of the binder phase in the slurry.
A covered slurry sample, approximately 500 mL, is set
on a counter overnight. The supernatant or binder phase
should completely separate from the flour, which is a
good indicator that the binder is stable. Then, a sample of
supernatant, approximately 20 mL, is placed in a closed
glass bottle and placed in a 60ºC (140ºF) oven for 24
hours. The sample can then be checked for any viscosity
change measured by a viscometer (initial and final). If the
supernatant is completely gelled, then the cause should
be determined. Usually, a failed gel test is the result of
high silica, low slurry turnover, old slurry, low pH, or
bacteria.7
29
Plate Weight: Plate weight is a measurement used to
determine slurry pickup on the wax pattern, and is conducted
using a metal plate. It measures not only slurry coverage and
adhesion, but also flow characteristics such as drainability.
It is mainly used on primary slurries but can also be used on
backup slurries. The plate weight can indicate the porosity
or permeability of the primary coating and the coating
thickness, which affects stucco penetration.7 Drainability
is attributed to the refractory material density, while film
thickness is affected by refractory particle size, distribution,
and morphology. A large well distributed particle size will
result in a thicker slurry deposition.6
Wet Film Thickness: The ability of slurries to be applied
with the proper thickness and with very little variation is
crucial during the prime coat of shell making. If stuccos are
unable to penetrate enough of the slurry thickness, the shell
is more likely to crack. If the stucco penetrates too much into
the prime coat, air can be pushed into the smooth inner shell
surface and cause surface roughness in the finished casting.
Zircon is a very dense material that forms very dense, thick
slurries that have excellent flow and coatability. Zircon
slurries apply evenly, and with little variation across a single
coat.
Permeability: Permeability is a measure of the ceramic
shell to transmit a gas or other fluid. A permeable shell will
prevent non-fill of the shell mold during casting. This test is
conducted by dipping a ping-pong ball attached to a ceramic
tube in the normal slurry dipping sequence. The specimen
is then fired to the normal preheat temperature, typically
1000ºC (1800ºF). A flow meter is attached to the ceramic
tube, which extends from the furnace, and permeability is
determined by passing nitrogen through the specimen.7
Thermal Expansion: Thermal expansion is an important
property of the ceramic shell as it affects casting dimensions.
The thermal expansion of the shell can be measured using a
dilatometer.7
Thermal Conductivity: The thermal conductivity of the
shell measures its ability to dissipate heat.7 Along with the
shell density and specific heat, it is an important measure of
the heat transfer characteristics of the shell.
Table 1. Recipe for 9.5 L (2.5 gal) zircon prime slurry.
30
Strength: The strength of the ceramic shell is determined
by measuring the modulus of rupture (MOR). This can be
done in the green, hot and fired stages. The green strength
measures how well the silica/refractory bonds are set. The
hot strength is an indication of the ability of the shell to
hold metal. The fired strength is measured after the shell
has cooled down and a lower fired strength suggests that
knockout will be easier. The MOR can be determined by
either a three point or four bend test.7
Creep: Creep is a measurement of the deformation of the
ceramic shell over time at elevated temperatures under an
applied load. It is a good measure of the performance of the shell
system during casting and solidification, and along with the hot
strength, can identify the tendency for the shell to bulge.
Experimental Procedure
In this phase of the study, the following measurements were
conducted on a set of six identical zircon prime slurries:
viscosity, bulk density, pH, temperature, wet film thickness,
prime coat bubble count, and plate retention.
Prime Slurry Formulation
In order to maintain consistent experimental conditions,
all six slurries tested were prepared in the same manner
and in the same laboratory over a two month period. The
laboratory room temperature was monitored regularly and
remained at a consistent 20-24ºC (68-75ºF). All slurries
were mixed with an 11 mm (4.5 in.) diameter stainless
steel propeller attached to a 1 hp DC motor, and the same
ingredients were used for all slurries. The recipe used for
all six zircon slurries is given in Table 1, and resulted in a
9.5 L (2.5 gal) slurry by volume. The colloidal silica and
distilled water were mixed first. A wetting agent and anti-
foam were mixed in shortly after. The binder was allowed
to mix for 5-10 minutes before zircon flour was slowly
sieved in to minimize air entrapment.
Slurry Viscosity Test
All viscosity measurements were taken with a single #5
Zahn Signature Series 90 viscosity cup. Each slurry’s
International Journal of Metalcasting/Winter 09
viscosity was checked four times daily at roughly equal
intervals. The first viscosity measurement was taken
exactly one hour after the completion of slurry mixing.
Before the measurements, the mixer was stopped and
the slurry was allowed to stand for thirty seconds. The
viscosity cup was dipped into the slurry, and emptied
after it was fully coated with slurry. Then, the viscosity
cup was dipped halfway into the middle of the container,
and gently lifted out vertically. A stopwatch was used
to measure the time from the lift until the slurry stream
broke one inch from the bottom of the viscosity cup.
Each Zahn cup measurement was repeated twice and the
values were almost identical. Since all measurements
were made by a single operator and a new Zahn cup
was utilized in these tests, a formal Gage R&R was
not performed. All measurements were recorded onto a
slurry data log.
Bulk Density Measurements
The bulk density of the 200S Continental zircon flour and
the slurries was estimated by filling a 100 mL graduated
flask to the 50 mL mark. The flask with flour or slurry was
weighed using a balance accurate to 0.001 g, and the weight
of the flask was subtracted to find the weight of the flour or
slurry. Bulk density was determined by dividing the mass of
flour/slurry by 50.
pH and Temperature Measurements
All pH and temperature measurements were made using a
digital Oakton data meter. A sample of slurry was removed
from the slurry container and transported to a separate lab.
The pH meter was calibrated with a standard buffer solution
before each measurement. The electrode was immersed
in a 200 mL slurry sample and the temperature and pH
were allowed to stabilize and then recorded. After each
measurement, the electrode was removed and thoroughly
cleaned with distilled water.
Slurry Wet Film Thickness Test
All wet film thickness measurements were made with two
Gardco Model “S” wet film gauges and a 76 x 127 x 3
mm (3 x 5 x 0.125 in.) glass plate. The glass plate was
dipped to a depth of 100 mm (4 in.) and allowed to drain
vertically, and then allowed to dry for five minutes. The
thickness gauge was pressed down onto the glass plate
and dragged 6 mm (0.25 in.), starting with the 7 mil (178
μm) edge. The test was repeated on two other spots, and
all three measurements were recorded. An average of the
three measurements was taken and recorded.
Prime Coat Bubble Test
One side of a disposable Petri dish was covered in masking
tape. The dish was dipped into the zircon slurry, drained, and
International Journal of Metalcasting/Winter 09
then coated with CE 60 200 mesh zircon stucco. The masking
tape was carefully removed, and the dish was positioned
next to an incandescent light bulb. The average number of
pinholes per square inch were observed and recorded by
holding a sheet of paper with a 1 inch square viewing area
cut out. The viewing area was placed over 5 different spots
in order to compute an average.
Slurry Plate Retention Test
A 100 mm square plate with a thickness of 1 mm was
cleaned and then rinsed and dried. The total surface area
of the plate was measured and recorded. The dry weight
of the plate was measured to the nearest 0.01 g. The plate
was then dipped into a zircon slurry for 5 seconds and
drained for one minute, and weighed to determine its
coated mass.
Results and Discussion
Results are presented for the following measurements
conducted on a set of six identical zircon prime slurries:
viscosity, bulk density, pH, temperature, and wet film
thickness. Data for the prime coat bubble count is not
presented as no bubbles or pinholes were found in any
of the tests. Data on the plate retention test are also not
presented as there was no significant variability among the
slurries.
As shown in Fig. 1, the viscosity of slurries tends to
increase with time. This is due to the evaporation of
water to the surrounding environment and due to the heat
generated during the slurry mixing process, both from
the friction of mixing itself, as well as the equipment
used. Fig. 1 shows spikes in viscosity in all five slurries
that were tested. The heat generated by the 1 hp motor
and thick stainless steel blade caused evaporation that
required careful slurry control. A timing system is
being installed to the mixer motors in order to minimize
overheating of the slurry. The initial viscosity drop in
a few of the slurries tested is likely due to air escaping
the slurry and decreasing the viscosity of the slurry.
Also, when a water addition was made to counteract
evaporation, a slight decrease in viscosity can be noted.
The average viscosity of each slurry during the life of
the slurry is shown in Fig. 2. The results suggest that
repeatable procedures allow the production of slurries
within a narrow range of viscosity, and that it is possible
to control the viscosity of slurries by careful balancing
of water lost due to evaporation. Control of water-
based slurries requires the use of distilled or de-ionized
water as well as close attention to impurities in any raw
materials. If the usage of the slurry is low, it may also
be recommended that some of the slurry be discarded
and replaced with fresh material. All measurements
were within the acceptable range of a viscosity cup
measurement of 20 to 30 s.
31
 Figure 1. Viscosity measurements on six zircon test slurries.

Figure 2. Average viscosity of all zircon slurries tested.

The measured densities of five tested slurries are shown in
Fig. 3. All five zircon slurries averaged a density of 3 g/mL.
The pH of each zircon slurry was measured once each day
of the slurry’s life. These measurements are shown in Fig. 4.
All recorded pH values were within an acceptable safe range
of 9.86 to 10.16. The addition of distilled water to the slurry
to counteract evaporation caused a small drop in pH. The
temperature of all tested slurries remained in an acceptable
range from about 24-24.5º C (75-76ºF), as seen in Fig. 5.
The slurries were transported to a different laboratory for
the measurements, and therefore, the actual temperature of
the slurry might be slightly higher, although the measured
variation should be similar. Temperature data for slurry 6
is missing.

32 International Journal of Metalcasting/Winter 09

 Figure 3. Measured densities of six zircon slurries.

Figure 4. Measured pH readings of six 100% zircon slurries.

International Journal of Metalcasting/Winter 09 33

 Figure 5. Measured temperature readings of ¿ve 100% zircon
slurries.

Figure . Measured Zet ¿lm thicNness of six 100% zircon slurries.

Fig. 6 shows the variation of wet film thickness across mils) over the life of the slurry. Fig. 7 shows that there
different slurries. In all but one of the slurries, the measured is very little variation of the measured wet film thickness
wet film thickness did not vary by more than 0.05 mm (2 across a single test sample.

34 International Journal of Metalcasting/Winter 09

 Figure . Measured Zet ¿lm thicNness across a 5x3x1 in. glass plate.
Summary
This paper documents a baseline evaluation of zircon prime
slurries, including tests and quality metrics to quantify its
behavior. Specifically, the following measurements were
conducted on a set of six identical zircon prime slurries:
viscosity, bulk density, pH, temperature, wet film thickness,
prime coat bubble count, and plate retention. These quality
metrics and other tests may be used to assess/benchmark
zircon slurries and potential alternatives, and evaluate their
performance compared to zircon.
Acknowledgments
This work was carried out as part of the project, “Identification
of Functional Zircon Alternatives for Investment Casting,”
sponsored by the Investment Casting Institute (ICI). The
authors would like to thank Nip Singh, S & A Consulting
Group LLP, Mike Hendricks, Ransom & Randolph, and
Mike Perry, ICI, for their input and support on this project,
and the ICI Board for their support.
REFERENCES
1. C. Whitehouse, J. Snow, B. Snyder, D. Scott, J.
Wright, and R. Rosemait, “A Study on Prime Coats
and Stucco Alternatives to Zircon,” 53rd Technical
Conference & Expo 2005 (Investment Casting
Institute, Montvale, NJ, 2005).
International Journal of Metalcasting/Winter 09
2. J. Snow and D. Scott, “Prime Slurries for Investment
Casting,” 47th Annual Technical Meeting 1999
(Investment Casting Institute, Dallas, TX, 1999).
3. M. Guerra, Jr., “Reducing zircon Sand Usage,” 54th
Technical Conference & Expo 2006 (Investment
Casting Institute, Montvale, NJ, 2006).
4. J. D. Bundy and S. Viswanathan, Survey on the
Use of Zircon and Zircon Alternatives (Investment
Casting Institute, Montvale, NJ, August 2007)
5. M. Bijvoet, “Practical Ceramic Shell Slurry
Preparation and Control,” 25th BICTA Conference
on Investment Casting, 2001 (Cast Metals
Federation, West Bromwich, UK, 2001).
6. G. Schiefelbein and M. Guerra, “Factors Effecting
Slurry Rheology,” Remet Corporation Report,
February 11, 1991.
7. J. C. Niles and A. T. Bozzo, “Ceramic Shell and
Slurry Characterization,” 51st Technical Conference
& Expo 2003 (Investment Casting Institute,
Montvale, NJ, 2003).
8. M. Guerra and G. W. Schiefelbein, “Review of Shell
Components, Shell Characteristics & Properties,
Refractory Selection for Primary Shell Coat,” 42nd
Annual Technical 1994 (Investment Casting Institute,
Montvale, NJ, 2005), Paper No. 24.
35
Technical Review & Discussion
Characterization of Zircon-Based
Slurries for Investment Casting
J. Bundy and S. Viswanathan,
Department of Metallurgical and Materials Engineering,
The University of Alabama, Tuscaloosa, AL, USA
Reviewer: The objective of the paper was to identify
alternatives to zircon and none were suggested.
Authors: The objective of the paper, as discussed in the
Abstract and Introduction, is the characterization of a
baseline zircon slurry. It is suggested that this information
could be useful in identifying alternatives to zircon.
Reviewer: Slurries in most Investment Casting operations
are mixed in tanks that are temperature controlled to avoid
the issues of viscosity changes. Plus slurry use is important
to determine tank size to keep the turnover at a constant rate
during the week.
Authors: Temperature control does NOT eliminate viscosity
changes, only minimizes them, since water is still lost due to
evaporation. The issues involving small research batches of
slurries and large commercial batches differ in degree but
not in kind.
Reviewer: What steps can be taken to recover (bad) slurries
other than adding distilled water?
Author Response: This is a good question. If the usage of
the slurry is low, it may also be recommended that some of
International Journal of Metalcasting/Winter 09
the slurry be discarded and replaced with fresh material.
This statement has been added to the revised paper.
Reviewer: This is a good summary of literature on the subject,
and would be of value as an overview and educational paper,
but has very little original work.
Author Response: We agree that the information in the
introductory and procedural sections of the paper is widely
known. However, the data on the baseline zircon slurry is
unique to this paper and is original work. Moreover, the
motivation for this work was that such controlled data is
difficult if not impossible to come by.
Reviewer: IC Slurry control is half science and half witchcraft
which is part of the problem, everyone has their own ideas.
Water base systems are somewhat more controllable than
those with ethyl-silicate.
Authors: The conflict between art and science pervades much
of casting technology and is not limited to investment casting.
Much of this may be attributed to the fact that tests are often
empirical and designed to monitor engineering behavior
for application to process control in industry, rather than
capture fundamental insights or behavior. Similarly, studies
that are reported are often carried out under industrial
conditions and don’t reveal critical details in order to protect
“proprietary information.” This practice results in data and
information that cannot be used by others, forcing them to
resort to “witchcraft” to solve problems. The motivation for
this work was to generate data under conditions that are
clearly stated and should be reproducible and useful to other
researchers, even if not directly applicable in industry.
37