Case Studies

Ceramic Shell


F-scrap

Complete System Conversion
Foundry F, a commercial foundry, was experiencing poor surface finish with their existing primary slurry and turned to the specialists at R&R for a solution. Within a month of converting the primary slurry, Foundry F requested a proposal for a complete system overhaul from R&R. R&R proposed a complete, user friendly system comprised of the following:

  • Primcote® binder
  • Matrixsol® LP colloidal silica
  • MXC Excel X2 blend
  • Ranco-Sil™ #2 fused silica (-120 mesh)

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Deluxcote concentrate

Deluxcote® Concentrate
R&R developed DELUXCOTE concentrate to provide investment casting foundries the opportunity to reduce shell coats; thereby reducing labor, total casting time and potentially material usage. Many casters find it hard to believe that a simple change in slurry products can significantly impact foundry economics – from shell room through casting. Here is the story of one foundry willing to challenge a shell material, proven in their production process for 10 years, with DELUXCOTE concentrate.
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Keycote

Keycote® System
The KEYCOTE system offers foundries exceptional slurry life, reduced labor and disposal costs and significant time savings. Foundries that have made the switch from their previous slurry systems have already recognized these advantages and more. The KEYCOTE system also features excellent wax adhesion characteristics, reduced surface defects, excellent wetting ability and microbial defense characteristics.
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Matrixcote system

Matrixcote® System
In an effort to improve casting results for a commercial casting foundry, whose existing shell was under performing, R&R tailored the MATRIXCOTE system to improve their casting results. This particular foundry was experiencing significant dewax cracking, positive metal and permeability defects, as well as losing money in scrap and rework. R&R was pleased to provide the foundry with the MATRIXCOTE system customized specifically to meet their needs.
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Shells Produced per 40 Hour Week

MXC Boost X2 Blend
Foundry X was experiencing increasing costs due to a rise in scrap on five product families. Their primary objective was to bring scrap rates back into control. Secondary objectives included reducing overall process throughput time wherever possible.
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Dewax Performance & Casting Fill

MXC Excel X2 Blend
With their existing system, Foundry Y experienced shell cracking; inconsistencies in shell thickness; trouble with dewaxing and casting fill; and difficulties with shell removal. They recognized the need for process improvement and partnered with the experts at R&R to create a system tailored to reach their casting goals.
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Foundry R Spalling Defect

Spalling Defect Elimination
Foundry R experienced spalling defects that varied in degree for several years. During this time, their spalling defect was tied to the age of the primary slurry; as the primary slurry increased in age, the amount of spalling defects increased. To eliminate the severity of the defect, Foundry R instituted a policy to change the primary slurry every six months. This operating practice worked for several years, until unexpectedly the spalling defect was no longer eliminated by simply changing the primary slurry.
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Industrial Mold


rantyre

R&R® Rantyre™ Tire Molding Plaster
A European tire mold foundry converted from their current investment product (Product X) to R&R RANTYRE tire molding plaster. After making the conversion, the foundry was pleased to achieve the following benefits.
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