The development of a self-disintegrating core-body for use in an art bronze-casting foundry which employs the ceramic-shell investment technique

摘要

The development of a disintegrating core-body for use in an art bronze foundry, which employs the ceramic shell investment process, begins with an investigation of four principal materials that will constitute the core formula. The specifications for the disintegration of the designed core-body formula fall within the parameters that are normally set and used in the ceramic shell art bronze casting process. The raison d’ être for the disintegrating formula is based on the premise that cement breaks down (spalling) after being subjected to heat above a certain temperature. It was shown that pure cement in the form of naked test bars 100 mm x 20 mm x 20 mm does indeed break down into separate pieces when fired to and above 9000C; where 9000C is the lowest recommended temperature required for sintering the ceramic shell investment mould. The addition of calcium carbonate to pure cement in the form of naked test bars, produced a more unified formula that did not break into separate pieces when fired to 9450C. However this combination of cement and calcium carbonate had a slow setting time of 12 hours and a shrinkage value of 2,3%, which were both above the parameters being sought for a quick-setting formula with a shrinkage value of below 1%. The combination of cement, plaster of paris and silica produced formulae that set within six hours and had shrinkage values of less than 1% but did not disintegrate within 72 hours. It was only after the addition of calcium carbonate to the these mixes that formulae resulted that set within six hours, had relatively low shrinkage values and showed signs of breaking up after 60 hours. It was further shown that by altering the ratios of cement, plaster of paris, calcium carbonate and silica, that the parameters for quick-setting formulae with shrinkage values of 1% and below, that also disintegrated within 55 hours, could be achieved. xvi It was also proved by subjecting these formulae to higher relative humidity conditions that the disintegrating times could be reduced and brought to below 48 hours. Selected formulae were then subjected to temperatures of between 9000C and 10000C. It was found that as the temperatures were increased so the disintegration times were reduced and were even further reduced under higher relative humidity conditions. It was found from the above experiments that the selected formula determined to be suitable in all respects as a disintegrating core-body was too difficult to remove from the hollow bronze cast when subjected to an actual bronze pour. Further experimentation using increased proportions of silica in the formula resulted in a final core-body that could be quickly and easily removed from its bronze cast as soon as the core-body had cooled to room temperature. The selected core-body formula (F21D) that was used in the final set of bronze casting procedures was found to function optimally when fired to a temperature of 9000C and could be quickly and easily removed from the bronze casts leaving a clean inner bronze surface, free from any remnants of the fired core. The document concludes by recording the delimitations and advantages of the final core-body formula F21D, as well as making recommendations based on these parameters for further study relating to disintegrating core-body formulations.