h i g h l i g h t sTo determine the interactions between CaZrO 3 filler and stucco materials during shell firing.To study the reaction between the CaZrO 3 facecoat and TiAl alloy during casting. The Al 2 O 3 stucco can react with CaZrO 3 filler to form (Zr, Ca)O 2 and CaAl x O y at 1650 C. O, Zr and Si ions from the ceramic moulds were observed to penetrate into the TiAl metal. The reaction products include (Ti, Zr) 5 (Al, Si) 3 and ZrAl 2 phase with high Ti ions solid solution.
a b s t r a c tResearch was carried out to determine the interactions between the filler and stucco materials in CaZrO 3 based facecoats during shell firing as well as between the facecoat and a TiAl alloy during the casting process. A 'flash re-melting' technique, which gives a similar heating profile to the actual investment casting process, was used to study the phase transformations in the shell moulds. The chemical inertness of the facecoat was then investigated using a sessile drop test using a Tie45Ale2Nbe2Mne0.2TiB alloy. In this study, the facecoat compositions and the interaction products between metal and shells were characterized using x-ray diffraction, scanning electron microscopy (SEM) and transmission electron microscopy (TEM). A severe interaction was found between CaZrO 3 filler and Al 2 O 3 stucco, which rapidly damaged the shell surface. As well as oxygen, zirconium and silicon ions from the shell moulds were also observed to penetrate into the TiAl metal to form (Ti, Zr) 5 (Al, Si) 3 phases in the metal/shell interfacial areas.