Ceramic Shell Casting

Additives Impact Shell Properties (Matrixcote® system)

The addition of fibers and polymers used in the MATRIXCOTE system slurries positively impacted shell properties

• Fibers

  • Increased shell thickness

• Polymers

  • Increased green strength and green deflection (elasticity) of the shell to reduce shell cracking during dewax

  • Decreased post fired shell strength to aid in shell removal

• Fibers and polymers

  • Offered potential for coat reduction due to increased shell strength and thickness per coat

Complete System Conversion

• Reduced coats from 9 to 7

• Reduced scrap rate from 14% to 1.4%

• Annual material savings: $19,200

Deluxcote® concentrate

• Created more uniform edges

• Eliminated 2 backup coats from existing process

• Labor savings: $50,000 (approx.)

  • Eliminated 1,000 hours of labor time​

• Reduced scrapped parts

  • Savings: $37,000 (approx.)

Keycote® system

• Foundry 1

  • Significantly improved slurry life to 22 months (more than 3 times previous slurry)

  • 20% cost reduction versus previous slurry

  • Reduced costs associated with dumping and rebuilding slurry

• Foundry 2

  • ​Significantly improved slurry life to 9 months (nearly 5 times previous slurry)

  • 32% cost reduction versus previous slurry

Matrixcote® system

• Reduced post fired strength by 35%

• Increased permeability by 128%

• Reduced cracking on round ring parts

• Significantly decreased scrap and rework with positive metal on parts

• Eliminated gas defects on certain parts

• Reduced make up time from 60+ minutes to 20 minutes

• Simplified slurry maintenance

MXC Boost X2 blend

• Reduced scrap and rework

• Increased shell production by 17%

• Decreased total process time by 14%

• Annual labor savings: $31,059

MXC Excel X2 blend

• Increased crack resistance by 10%

• Increased dewax and casting fill by 190%

• Decreased knockout resistance by 28%

Spalling Defect Elimination

• Optimized the slurry shell building process to reduce the potential for spalling defects on castings

• Eliminated the spalling defect without issue

• Realized the benefits of decreased scrap and rework

Solid Mold Casting

Rantyre™ tire molding plaster

• Reduced mold cracking

  • 33% increase in green (wet) compressive strength​

• Reduced finishing coats and improved as-cast surface finish​

  • Surface tension agents reduce air bubble defects​

• Tighter tolerances, plus reduced warping and cracking

  • Superior thermal stability