Professional Documents
Culture Documents
Ralph Carter
Materials Engineer
Ransom & Randolph
Maumee, Ohio, USA
Introduction
In any artistic endeavor or manufacturing process, different techniques are sometimes
tried in order to enhance certain results. Sometimes these techniques have predictable
results, while others are quite experimental. A good example of this is using higher
water-to-powder ratios for some castings and lower ratios for others. In fact, some
investment manufacturers provide for this flexibility by recommending a range of water
to powder ratios. Lower water to powder ratios are advised for large, heavy pieces and
higher ratios are recommended for smaller and more detailed pieces.
It is commonly known that the investment strength, working time and fluidity are
dependant on the water-to-powder ratio. However, the degree of dependence might not be
as well known. Also, while taking action to enhance one property, another lesser-known
property may be overlooked and changed undesirably. This may lead to casting defects.
Because of this, investments are designed to be robust enough to provide some stability,
despite changes in the water-to-powder ratio. But, in order to avoid large adverse
changes, the recommended water-to-powder ratio range is limited.
Some jewelers have used this technique of changing the water-to-powder ratio quite often
and from their experience can easily predict the results. Others may not have the luxury
of experience, thus this technique may be more experimental. For both the experienced
and novice caster, it would be helpful to understand what investment properties are
affected by the water-to-powder ratio and more importantly to what degree.
This paper explores how the various properties of a gypsum-bonded investment change
as a function of the water-to-powder ratio. This paper also discusses how these changes
can affect mold and casting attributes and reinforces the importance of using the water
to-powder ratio range set by investment manufacturers.
Background
The ratio of the amount of water to the amount of investinent powder is commonly
expressed as the water-to-powder ratio (w:p), having units of milliliters of water per
100grams of powder. A w:p of 40ml water per 100 grams powder is sometimes written as
40/100 or simply as 40 or even 0040. Some investment manufacturers recommend that
their gypsum-bonded jewelry investments be used at a w:p in the range of39 to 42 [1].
Others may direct only a specific w:p like 38, instead of a range.
Gypsum-bonded investments contain various types of silica as well as plaster and many
controlling chemicals. The silicas act as a refractory material. Plaster, calcium sulfate
hemihydrate (CaS04.J 12H20), is used to produce a bonding material. Chemicals are used
to control the properties of working time and fluidity as well as to accentuate various
other investment properties.
plaster is an interesting component to investments in that it can be mixed with water to
create a fluid and will react with this water to harden into a solid mass. As a fluid it can
be poured in and around patterns to fill in detailed designs. As a solid it will hold its form
and withstand the rigors of metal casting. When mixed with the proper refractories and
chemicals, plaster retains these characteristics and is thus well suited for jewelry
investments.
The primary product of the reaction between plaster and water is gypsum, calcium sulfate
dihydrate (CaS04.2H20). Gypsum acts as the binding agent, holding the refractory
material together in the desired shape. This reaction is represented in the following
balanced chemical equation.
The double arrow indicates that this reaction is reversible. It is during the investment
burnout that this reaction is reversed. At about 262F (128C) [2] gypsum will liberate
some of the molecularly attached water to form plaster. Plaster can be forced to liberate
its molecular water by heating to about 325F (163C) [2]. The resulting compound is
calcium sulfate anhydrite (CaS04). It is important to remove all of the water prior to
casting, so that it does not escape during casting and cause defects or even splash molten
metal out of the mold.
Using the above chemical equation and the molecular weights of each species, it can be
shown that 18.6grams of water is needed to fully convert 100grams of plaster to gypsum.
This ratio can be converted to the common units ofw:p, by using the density of water,
which is O.9977grams/ml at 72.5F (22.5C) [3]. This results in a w:p of 18.7, which is
considerably lower than the recommended w:p for gypsum jewelry investments. This is
because this w:p only accounts for the water necessary to convert plaster to gypsum.
Additional water is always needed to create a mix fluid enough to pour.
The amount of additional water required depends on the type of plaster used, particle size
distribution ofthe plaster and silicas, adhesion between particles and the controlling
chemicals added to the investment [4]. Because of these factors, investment
manufacturers spend great effort to assure the raw materials are as consistent as possible.
Any remaining slight inconsistencies in the raw materials are compensated for by the use
of controlling chemicals, before investment material is sent out for use.
Investment manufacturers, as well as industry experts, have stressed measuring both the
water and powder accurately. Their reasons are many. One reason is to assure that the
mixed investment is not too thick. It has been suggested that if the mixed investment is
too thick, fine details may not be filled and air bubbles may not readily escape [5].
Another reason is to assure the proper mold strength. It is thought that a weak
investment causes a rough surface and possible :fins on the castings [5]. Other reasons
given are to
assure proper working time, permeability, setting expansion, thermal expansion, smooth
casting surface, no fins, no watermarks and ease of removing investment from casting
pieces [5, 6].
In this study, several investment properties were investigated, varying only the w:p from
34 to 46. Castings were also made and evaluated.
Procedures
Ultra- Vest investment was chosen for this study simply because of it's familiarity and
convenience to the author. The instructions for this product recommend a w:p of 39 for
large castings and 42 for delicate castings [1]. This w:p is similar to other gypsum-based
jewelry investments.
The investment properties measured were pour time, set time, slump, set expansion, green
compressive strength, fired compressive strength and surface hardness. A brief description
of the procedures used to measure these properties is below. All tests were performed with
both the water and powder at 72-74P (22.2-23.3C). The water used was first de-ionized.
This was done because of the dependence that investment properties
have on temperature and water quality [7].
Pour Time
Pour time is similar to working time; but there is a subtle difference. The working time is
the amount of time from when all the powder is added to the water until the investor feels
that the mixture is too viscous to continue to work or manipulate [4 J. It is easy to
understand how this will depend on the user's preference and the application. On the
other hand, the pour time, as it is described in the Ransom & Randolph ISO 9002
procedures, is less subjective.
Pour time is measured by the following method. The amount of water and investment are
carefully measured. As soon as the powder is added to the water, a timer is started. The
powder is wet out by hand with a spatula and then mechanically mixed for 20seconds.
For repeatability, the mixing is done with a mixing head of a specific design and
specified rotations per minute. The mixed investment is poured from one bowl to another
every 15seconds. The timer is read when the investment becomes so thick it will not pour
out of the bowl. The elapsed time is recorded as the pour time.
Set Time
The R&R procedure for set time is the vicat set time. This is the amount oftime from
when the powder is completely added to the water until it reaches a well-defined ,
hardness. When the investment hardens enough to keep the vicat needle from penetrating
more than one millimeter, the elapsed time is read as the set time. The vicat needle has a
diameter of 1.0mm and has 300gm weight behind it. At this point in the setting process,
the investment strength is only approximately 22% of its fully cured strength [4]. The
investment would not be strong enough for further processing for another 1-2hours.
Slump (Fluidity)
The investment fluidity is measured using the R&R procedure for slump. The investment
is mixed in the same manner as it is for the pour time test. It is then poured into a cylinder
that is resting on a glass plate. The cylinder is 2" tall and has an inner diameter of 13/8".
Using a spatula, the investment is "struck-off' level with the top of the cylinder. At
exactly the 2-minute mark, the cylinder is lifted off the glass. The investment will spread
out on the glass plate in the shape of a disk. Very thin investments will result in a large
disk and conversely, thick investments result in a small disk. The diameter of the disk is
measured in inches and reported as the slump. Because jewelry investments exhibit
thixotropic characteristics, this test is measured after a specified amount of mixing and
at a specified time.
Set Expansion
As the investment sets, it will expand. This expansion is commonly referred to as the
set expansion, The mechanism for this stems from interfering outgrowths from the
many nuclei of crystallization of gypsum [4]. Set expansion can be controlled by
chemical additions to the investment. This property is important to those who are
concerned with dimensions. The actual set expansion realized is dependant on the
geometries of the investment's rigid boundaries, as alluded to by Ott [5]. In other
words, the investment will expand most in the direction of least resistance. This can
cause distortions in the pattern, particularly ifit is made of very soft wax [4].
There are a few ways to measure set expansion [4, 5]. For this study the set expansion
was measured according to the R&R ISO 9002 quality procedures. Figure 1 shows the set
expansion apparatus used. Each side ofthe apparatus is bound, except the side of the
dilatometer (left in Figure 1) and the top.
Figure 1
Mixed investment is poured into the apparatus, the dial is set to zero and one hour after
the investment sets the result is read. Since the length of the sample cavity is
lOOmmlong and the dial has O.Olmmdivisions, the dial can be read as percent linear
change or
percent linear set expansion.
Green Compressive Strength
Green compressive strength refers to the compressive strength 2hours after the mixed
investment is considered set by the vicat test method. Cylinders, with a cross sectional
area of Iirr', are made using the forms pictured in Figure 2. At the appropriate time, the
force required to destructively compress each cylinder is measured using the device
pictured in Figure 3. This device measures the force in pounds and given the cross
sectional area of the cylinders, a pressure in pounds per square inch (psi) is obtained.
The mean offive cylinders is reported.
Figure 2
Figure 6
Fired Compressive Strength
The fired compressive strength is measured similarly to the green compressive strength.
The only difference is that the cylinders are first fired using the burnout schedule
recommended for the investment. The samples are then cooled slowly to room
temperature before crushing.
The firing process tremendously weakens gypsum investments; therefore the fired
strength is lower than green strength. Some investments are weakened inore than others,
Casting
Castings were made at several water-to-powder ratios. The investment was mixed until
the three-minute mark on a Hobart model C-l 00, with a wire whip attachment. The
investment was vacuumed for 20seconds. The 4" diameter by 5" high flasks were filled
Figure 7
to the top of the pattern and vacuumed for lminute. The flasks were then filled the rest of
the way and set aside for hardening. The recommended burnout cycle was used. The
flasks were 950F (5100C) when cast. A brass alloy 0[60% copper and 40% zinc was
centrifugally cast at 1995F (1091C). The same pattern was used for each w:p.
It should not be assumed that all gypsum investments behave in the exact same manner as
the one used here. Other gypsum investments should, however, trend in at least a similar
manner.
Pour Time
Chart 1 shows the dependence of pour time on w:p. In almost a linear fashion, the pour
time is increased as the w:p is increased. In the recommended w:p range of39 to 42~ the
pour time changed about 1.25minutes. This should be enough flexibility for the investor,
without risking other properties, by going outside the recommended w:p range.
In applications where this range of pour times is not enough, then possibly other process
parameters should be looked into. These include mixing time, vacuum times and the
number of flasks invested at a time. The pour time can also be slightly increased by
decreasing the temperature of the investment and water [7].
Set Time
The set time results are shown in Chart 2. This relationship is almost linear as well. The
slope is a little greater than the pour time's. Therefore, as the w:p increases, the
difference between the set time and pour time increases slightly.
After the flasks are set aside for hardening, it is desirable to have the set time occur as
quickly as possible. This is for the purpose of decreasing the chance of water separating
from the investment and causing watermarks. This data shows that if the w:p is increased,
the set time will be delayed. Thus, the probability of water separating is increased. It is
important to note that some investments will not cause watermarks regardless ofthe set
time.
Slump
Chart 3 shows the slump versus w:p. As expected, the investment gets thinner with
increased w:p's. What is more interesting is the magnitude of change within the
recommended w:p range. In the recommended range of39 to 42, the slump changes by
more than %". This is certainly more than enough flexibility to satisfy the investor's
preferences in fluidity.
Below the recommended w:p range, the investment becomes thick and is not easy to
work with. It is easy to see how air could become trapped next to the wax patterns and
cause casting defects. Above the recommended w:p range, the investment becomes so
thin it is difficult to mix without it splashing out of the mixer. Thinner mixes can
Chart 4 shows the dependence of the set expansion on w:p. The chart demonstrates that
set expansion is inversely proportional to w:p. At higher w:p's, there is less set
expansion, because the nuclei of crystallization are more spread out. This allows for the
crystals to progress through much of its growth before pushing against a neighboring
crystaL In contrast, at lower w:p' s there are more nuclei of crystallization per unit
volume, resulting in more growth interaction. This in turn results in greater net set
expansion [4].
.
As mentioned earlier, this property is important for the dimensional precision of the
casting. When contemplating changing the w:p, it may be prudent to consider that
the dimensions of the finished piece could be adversely affected.
Green Compressive Strength
As shown in Chart 5, the green compressive strength measured at two hours is inversely
proportional to w:p. In the recommended w:p range of39 to 42, there is modest change in
the green strength, in fact about 37psi. This stability can be helpful ifa higher w:p is
desired for something like fluidity, but losing mold strength is a concern. Outside the
recommended range, the strength changes more dramatically. A high w:p could weaken
the investment too much. This increases the probability of small cracks forming in the
mold, which could result in fins on the casting. A rough surface may also be observed
if the investment is weakened too much [5].
Fired Compressive
Strength
Chart 6 shows the fired compressive strength as a function ofw:p. Because fired
compressive strength is measured after firing and cooling, it is more of an indication
of the strength after casting. Therefore, it may impart some information on the ease of
removing the casting from the mold. As the w:p is increased, the fired compressive
strength decreases.
The slope ofthis relationship is fairly consistent, except for the lower fringe w:p, where
there is a large increase in fired strength. This will result in more energy being required
to remove the casting. This is, of course, not the only factor affecting the ease of casting
removal. There are formulation factors as well as raw material quality factors, for the
investment manufacturers to consider, which affect the casting removal process and / or
ability to quench.
Durometer
Type A
As with fired compressive strength, the Durometer readings may indicate ease of casting
removal. Chart 7 shows how the Durometer relates to changing w:p's. It has a fairly
linear dependence on the w:p, at least in the range studied. This does not show a large
increase in strength at 34, as did the fired compressive strength. This shows the
limitations of the Durometer reading. For harder materials there are other types of
Durometers. Perhaps a Durometer type C would have revealed the upswing that fired
compressive strength showed.
Investing I Casting
At w:p's above the recommended range, the investment was so fluid it splashed out of the
Hobart mixer, when mixed at normal speed. During the vacuuming steps, the investment
rose much higher than normal. After the flask was set aside for hardening, water did not
separate out or pool. The mold withstood the forces of centrifugal casting. The castings
looked fine. The surface appeared to be as smooth as the other castings. Because the
water did not separate, there were no watermarks. There were no fins. However, there
were a few air bubbles.
At w:p's below the recommended range, the investment was very thick, It was even
difficult to pour into the flask. During vacuuming, the investment did not rise up much
at all. These castings looked fine as well. They filled completely and there were no air
bubbles. The lack of air bubbles is contrary to what was expected. Conventional wisdom
suggested that at lower w:p's there would be more air bubbles [5]. However, air
entrapment is also influenced by the quality of vacuum.
The castings did not have the defects that investment manufacturers and industry experts
associate with exceedingly high or exceedingly low w:p' s [1, 4, 5, 6]. A rush to
conclude that a w:p outside the recommended range will not result in defects is simply
not warranted here. Outside the designed w:p range, the probability of certain defects
might
Figure 5
To confirm this, a non-premium brand of investment was used to make castings and
compare. This second brand of investment was used in the same manner and with the
same patterns. At w:p's above the recommended range severe watermarks resulted. It
might be possible to see them on the casting on the right in Figure 5. The molds held up
for the most part, except for the watermarks. Air bubbles were present to about the same
degree on each casting made with this investment.
These results show that there is some difference in stability between the two investments.
However, the fact that there were no fins on the castings indicates that the pattern used
may not have stressed the molds.
Summary
There are several variables that have to be considered during the manufacturing of
jewelry. Having a clear understanding of what affects these variables and to what degree
is important. This knowledge can save time having to salvage poor castings or even
having to remanufacture them. To help investors obtain consistent results, investment
manufacturers stress the importance of using a w:p in a specified range. Within this
range, some properties are fairly stable. Other properties change, thus giving the jeweler
some flexibility.
It has been shown that the pour time, set time and slump each increase with increasing
w:p. The slump is more responsive than the others. This allows the investor to change the
fluidity without changing the other properties as much. The set expansion and strength
decreased with increasing w:p.
According to investment manufacturers and industry experts, the changes realized in
these properties are, at times, the cause of certain defects. A long pour time and set time
increase the probability of watermarks in some investments, especially if they are not
mixed long enough. The set expansion can cause changes in dimensions. A weak
investment can cause fins to form and as well as a rough surface to result on heavy
castings. Because these properties are dependent on w:p and they affect casting results,
the w:p is very important to control.
Appendix
W:P
Pour
Time
(min)
Set
Time
(min)
Slump
(in)
Set
Exp.
Green
(psi)
Fired
(psi)
Dur.
Type
A
34
8.50
16.25
2%
1.33%
546
120
77
36
10.25
18.00
39/16
1.28%
486
84
71
38
12.00
20.25
4~
0.99%
408
81
67
40
13.00
22.00
0.87%
386
75
63
42
13.75
22.75
5 3/8
0.78%
360
66
61
44
15.00
24.50
5
11/16
0.65%
263
60
56
46
16.50
27.50
0.62%
234
48
48
15/16
References
1. Ransom & Randolph, "Application Instructions Ultra-Vest Jewelry Investment",
Ransom & Randolph, July 1999
2. Petersen, Donald 1., Kaleta, Norbert W., Kingston, Larry W., "Encyclopedia of
Chemical Technology," Kirk-Othmer, 4th ed., vol. 4, pg. 813
3. Dean, John A., "Lange's Handbook Of Chemistry," McGraw-Hill, Inc., 14thedition
1992, pg 5.87
4. Phillips, Ralph W., "Skinner's Science of Dental Materials," WB. Saunders Co., 9th
ed., 1991, pg. 70-78 & 393-411
6. Ransom & Randolph, "Ransom & Randolph Setting Jewelry Standards Worldwide,"
Ransom & Randolph, section on Casting Defects: Potential Causes and section on
Questions & Answers.
7. Carter, Ralph, "The Santa Fe Symposium On Jewelry Manufacturing Technology
Jumlah air tambahan yang dibutuhkan tergantung pada jenis plester digunakan, distribusi ukuran partikel tersebut yang plester dan
silika, adhesi antara partikel dan bahan kimia pengendalian ditambahkan ke investasi [4]. Karena faktor-faktor ini, investasi
produsen menghabiskan upaya besar untuk menjamin bahan baku adalah sebagai konsisten mungkin. Tersisa sedikit inkonsistensi
dalam bahan baku dikompensasikan dengan penggunaan pengendalian bahan kimia, sebelum bahan investasi dikirim keluar untuk digunakan.
Produsen investasi, serta pakar industri, telah menekankan mengukur baik air dan bubuk akurat. Alasan mereka banyak. Salah satu
alasannya adalah untuk memastikan bahwa investasi campuran tidak terlalu tebal. Ia telah mengemukakan bahwa jika investasi campuran
terlalu tebal, rincian halus tidak dapat diisi dan gelembung udara mungkin tidak mudah melarikan diri [5].
Alasan lain adalah untuk menjamin kekuatan cetakan yang tepat. Diperkirakan bahwa investasi yang lemah menyebabkan permukaan
kasar dan mungkin: sirip pada coran [5]. Alasan lain yang diberikan adalah untuk
menjamin waktu kerja yang tepat, permeabilitas, pengaturan ekspansi, ekspansi termal, permukaan pengecoran halus, tidak ada sirip,
tidak ada tanda air dan kemudahan menghapus investasi dari pengecoran potongan [5, 6].
Dalam studi ini, beberapa properti investasi diselidiki, hanya berbeda w: p dari
34-46. Tuang juga dibuat dan dievaluasi.