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<p>In investment casting process, a primary coat of zircon sand over the wax pattern, followed by successive backup coatings using Fused Silica Sand (FSS) are performed for making the shell. This study investigates the potential application of Copper Slag (Cu Slag) as an alternative to FSS as a backup coating material for shell molding. In this study, shell molds were prepared using Cu Slag as the stucco material for the backup layers and were compared with the shell mold properties against standard FSS-based molds. The mold characteristics such as flexural strength and hardness were evaluated in both the green and fired states. Permeability is evaluated at room temperature after firing, yielded values of 1.31 × 10<sup>-13</sup> m<sup>2</sup> for the FSS mold and 4.09 × 10<sup>-14</sup> m<sup>2</sup> for the Cu Slag mold. Furthermore, Aluminum A356 alloy was cast using both types of shell molds. The castings produced from Cu Slag molds exhibited an average surface roughness of 1.296 µm, a Brinell hardness of 74.36 BHN, tensile strength of 141 MPa and porosity of 1.11%. A comparative phase analysis and microstructure in both sets of castings indicate that Cu Slag is a viable substitute for FSS in investment casting applications. However, the further study is required at industrial scale to understand its scalability and sustainability.</p>

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Development of A356 Alloy Casting using Copper Slag as Backup Coating Material in Investment Casting Process

  • 期刊论文

  • 发表日期：

    2025年12月12日

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  • Sourabh Jain,
  • Ramesh Kumar Nayak

摘要

In investment casting process, a primary coat of zircon sand over the wax pattern, followed by successive backup coatings using Fused Silica Sand (FSS) are performed for making the shell. This study investigates the potential application of Copper Slag (Cu Slag) as an alternative to FSS as a backup coating material for shell molding. In this study, shell molds were prepared using Cu Slag as the stucco material for the backup layers and were compared with the shell mold properties against standard FSS-based molds. The mold characteristics such as flexural strength and hardness were evaluated in both the green and fired states. Permeability is evaluated at room temperature after firing, yielded values of 1.31 × 10-13 m2 for the FSS mold and 4.09 × 10-14 m2 for the Cu Slag mold. Furthermore, Aluminum A356 alloy was cast using both types of shell molds. The castings produced from Cu Slag molds exhibited an average surface roughness of 1.296 µm, a Brinell hardness of 74.36 BHN, tensile strength of 141 MPa and porosity of 1.11%. A comparative phase analysis and microstructure in both sets of castings indicate that Cu Slag is a viable substitute for FSS in investment casting applications. However, the further study is required at industrial scale to understand its scalability and sustainability.