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Case Studies
![Foundry-R_Spalling-Defect-Elimination.jpg](https://static.wixstatic.com/media/cc5f22_b77ea73268f64cc4abcbe6462f13a134~mv2.jpg/v1/fill/w_296,h_296,al_c,q_80,usm_0.66_1.00_0.01,enc_auto/Foundry-R_Spalling-Defect-Elimination.jpg)
Participate in a Case Study
Has R&R helped you make a minor product or process change or a complete system overhaul? Want to share your thoughts with your fellow casters?
Email our marketing team at: Marketing@ransom-randolph.com.
Ceramic Shell
![Matrixcote-system-logo.jpg](https://static.wixstatic.com/media/cc5f22_84eb6c4b39ad495b983032bc309ba519~mv2.jpg/v1/fill/w_146,h_146,al_c,q_80,usm_0.66_1.00_0.01,enc_auto/Matrixcote-system-logo.jpg)
Additives Impact Shell Properties (Matrixcote® system)
The addition of fibers and polymers used in the Matrixcote system slurries positively impacted shell properties
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Fibers
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Increased shell thickness
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Polymers
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Increased green strength and green deflection (elasticity) of the shell to reduce shell cracking during dewax
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Decreased post fired shell strength to aid in shell removal
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Fibers and polymers
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Offered potential for coat reduction due to increased shell strength and thickness per coat
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![Complete-System-Conversion-Scrap-Rate-Reduction.jpg](https://static.wixstatic.com/media/cc5f22_8fe8d0afbfe94de087c8b82303eca069~mv2.jpg/v1/fill/w_146,h_146,al_c,q_80,usm_0.66_1.00_0.01,enc_auto/Complete-System-Conversion-Scrap-Rate-Reduction.jpg)
Complete System Conversion
Within a month of converting the primary slurry to Primcote binder, Foundry F
requested a proposal for a complete system overhaul
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Reduced coats from 9 to 7
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Reduced scrap rate from 14% to 1.4%
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Annual material savings: $19,200
![deluxcote-concentrate.jpg](https://static.wixstatic.com/media/cc5f22_82b07a12382947668980ed24f51010eb~mv2.jpg/v1/fill/w_146,h_146,al_c,q_80,usm_0.66_1.00_0.01,enc_auto/deluxcote-concentrate.jpg)
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Created more uniform edges
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Eliminated 2 backup coats from existing process
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Labor savings: $50,000 (approx.)
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Eliminated 1,000 hours of labor time
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Reduced scrapped parts
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Savings: $37,000 (approx.)
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![keycote-system.jpg](https://static.wixstatic.com/media/cc5f22_89ec2a8df28a4c6990be35d935cabbb9~mv2.jpg/v1/fill/w_146,h_146,al_c,q_80,usm_0.66_1.00_0.01,enc_auto/keycote-system.jpg)
Foundry 1
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Significantly improved slurry life to 22 months (more than 3 times previous slurry)
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20% cost reduction versus previous slurry
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Reduced costs associated with dumping and rebuilding slurry
Foundry 2
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Significantly improved slurry life to 9 months (nearly 5 times previous slurry)
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32% cost reduction versus previous slurry
![Matrixcote-System-Relative-Comparison-to-Existing-Shell.jpg](https://static.wixstatic.com/media/cc5f22_139302c5eaab4db088990a5ccc9d41e7~mv2.jpg/v1/fill/w_146,h_146,al_c,q_80,usm_0.66_1.00_0.01,enc_auto/Matrixcote-System-Relative-Comparison-to-Existing-Shell.jpg)
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Reduced post fired strength by 35%
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Increased permeability by 128%
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Reduced cracking on round ring parts
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Significantly decreased scrap and rework with positive metal on parts
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Eliminated gas defects on certain parts
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Reduced make up time from 60+ minutes to 20 minutes
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Simplified slurry maintenance
Solid Mold
![rantyre.jpg](https://static.wixstatic.com/media/cc5f22_1a473dde2beb4323832cbbbb7a4976fa~mv2.jpg/v1/fill/w_146,h_146,al_c,q_80,usm_0.66_1.00_0.01,enc_auto/rantyre.jpg)
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Reduced mold cracking
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33% increase in green (wet) compressive strength
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Reduced finishing coats and improved as-cast surface finish
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Surface tension agents reduce air bubble defects
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Tighter tolerances, plus reduced warping and cracking
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Superior thermal stability