Effect of zirconia as inorganic binder on molds for precision casting

Sand‐casting molds suffer from surface defects and low strength. An organic–inorganic binder conversion process, wherein an organic binder is converted to an inorganic binder, has been proposed to increase the application temperature of the sand‐casting mold and simplify the manufacturing process fo...

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Bibliographic Details
Published in:International journal of applied ceramic technology 2024-09, Vol.21 (5), p.3678-3685
Main Authors: Choi, Hyun‐Hee, Kim, Bong‐Gu, Kim, Min‐Gyu, Kim, Eun‐Hee, Kim, Jong Young, Kim, Jung Hun, Son, Jeong Hun, Yang, SeungCheol, Yang, Byungil, Byeun, Yun‐Ki, Jung, Yeon‐Gil
Format: Article
Language:English
Subjects:
Casting
Casting defects
glass
inorganic binder
Investment casting
Liquefaction
Mechanical properties
Molds
Operating temperature
organic–inorganic conversion process
Sand casting
Silicon dioxide
SiO2–Na2O–ZrO2 ternary inorganic binder system
sodium silicate
Sodium silicates
Surface defects
Zirconium dioxide
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Summary:Sand‐casting molds suffer from surface defects and low strength. An organic–inorganic binder conversion process, wherein an organic binder is converted to an inorganic binder, has been proposed to increase the application temperature of the sand‐casting mold and simplify the manufacturing process for precision casting. However, the usable temperature of the typical SiO2–Na2O binder system is limited to approximately 1000°C owing to the low liquefaction temperature of the compound. The resulting glass phase (Na2SiO3) exhibits low viscosity, and the casting of large objects results in low strength. Therefore, in this study, we propose a SiO2–Na2O–ZrO2 ternary inorganic binder system; the addition of zirconia (ZrO2) into sodium silicate (Na2SiO3) as an inorganic binder was expected to increase the operating temperature of the mold and improve its mechanical properties. The results confirmed that the addition of ZrO2 improved the mechanical properties by preventing the formation of Na2SiO3. In addition, a higher sintering temperature corresponded to smaller and larger amounts of Na2SiO3 and Na2ZrSiO5, respectively, and thus a higher strength. Therefore, we expect our developed ternary inorganic binder system to be highly advantageous for producing molds for high‐temperature and precision casting.
ISSN:1546-542X
1744-7402
DOI:10.1111/ijac.14795