Investigation of Part Accuracy and Surface Roughness in Rapid Freeze Prototyping Based Investment Casting

The study as described in this paper is aimed at investigating the dimensional accuracy and surface finish of metal parts made by investment casting with ice patterns generated by rapid freeze prototyping. The process of investment casting with ice patterns is described and contrast with conventional investment casting with wax patterns is made. The selection of binder material for ceramic slurries and the need for an interface agent to separate the ice pattern from the ceramic slurry in the mold making process are discussed. The accuracy and surface finish of ice patterns and of the metal castings are presented and discussed. The parts used in this investigation include cylinders with vertical and slant walls and a turbine impeller.The authors gratefully acknowledge the financial support from the National Science Foundation grants (DMI-0128313 and DMI-0140625) and the Research Board of University of Missouri at Rolla.Mechanical Engineerin