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In this work, steel fibers were added into a silica sol binder to prepare shells for investment casting. The green strength, high-temperature self-load deformation, heat transfer, and fiber dispersion in the shell were investigated. The effect of ultrasonic power on fiber dispersion in the shell and the silica sol was studied and discussed. The results suggest that, with a fiber addition amount of 0.15%, an ultrasonic power level of 1200 W can completely disperse the fibers in silica sol. It has been found that the reinforcement effect is the best when the fiber addition amount is 0.15%. When the ultrasonic power level was 1200 W, the strength reached the maximum value of 3.29 MPa, which was 0.74 MPa higher than that without ultrasonic agitation (2.55 MPa). Under ultrasonic agitation, the fibers were in monofilament state and well-bonded with the shell. Steel fibers have good thermal stability at high temperature and still exists in the shell; thus, they can support the shell and prevent its deformation. Under an ultrasonic power level of 1200 W and fiber addition amount of 0.15%, the high-temperature self-load deformation of the shell was 0.44%. It is concluded that, the more uniform the dispersion of the fibers, the better the heat dissipation performance of the shell.

Preparation of steel fiber-reinforced shells for investment casting using ultrasonic-assisted dispersion