Case Studies

Participate in a Case Study
Has R&R helped you make a minor product or process change or a complete system overhaul? Want to share your thoughts with your fellow casters? Let us know!
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
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Fibers
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Increased shell thickness
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Polymers
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Increased green strength and green deflection (elasticity) of the shell to reduce shell cracking during dewax
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Decreased post fired shell strength to aid in shell removal
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Fibers and polymers
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Offered potential for coat reduction due to increased shell strength and thickness per coat
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Complete System Conversion
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Reduced coats from 9 to 7
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Reduced scrap rate from 14% to 1.4%
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Annual material savings: $19,200
Deluxcote® concentrate
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Created more uniform edges
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Eliminated 2 backup coats from existing process
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Labor savings: $50,000 (approx.)
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Eliminated 1,000 hours of labor time
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Reduced scrapped parts
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Savings: $37,000 (approx.)
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Keycote® system
Foundry 1
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Significantly improved slurry life to 22 months (more than 3 times previous slurry)
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20% cost reduction versus previous slurry
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Reduced costs associated with dumping and rebuilding slurry
Foundry 2
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Significantly improved slurry life to 9 months (nearly 5 times previous slurry)
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32% cost reduction versus previous slurry
Matrixcote® system
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Reduced post fired strength by 35%
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Increased permeability by 128%
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Reduced cracking on round ring parts
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Significantly decreased scrap and rework with positive metal on parts
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Eliminated gas defects on certain parts
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Reduced make up time from 60+ minutes to 20 minutes
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Simplified slurry maintenance
MXC Boost X2 blend
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Reduced scrap and rework
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Increased shell production by 17%
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Decreased total process time by 14%
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Annual labor savings: $31,059
MXC Excel X2 blend
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Increased crack resistance by 10%
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Increased dewax and casting fill by 190%
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Decreased knockout resistance by 28%
Spalling Defect Elimination
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Optimized the slurry shell building process to reduce the potential for spalling defects on castings
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Eliminated the spalling defect without issue
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Realized the benefits of decreased scrap and rework
Solid Mold Casting
Rantyre™ tire molding plaster
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Reduced mold cracking
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33% increase in green (wet) compressive strength
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Reduced finishing coats and improved as-cast surface finish
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Surface tension agents reduce air bubble defects
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Tighter tolerances, plus reduced warping and cracking
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Superior thermal stability
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