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Urea is a low cost material with thermal and mechanical properties suitable for use in investment casting pattern molding compounds. Conventional compounds are made by a “cooking” process wherein the urea is added to and dissolved in an aqueous solution of a water soluble polymer followed by evaporation of the water. Here we describe novel formulations based on either polyvinyl alcohol (PVOH) plasticized by glycerol or ethylene vinyl acetate (EVA) resins together with wax that can be prepared by a facile twin-screw compounding process. The thermo-mechanical properties of these compounds were characterized using differential scanning calorimetry (DSC), thermo gravimetric analysis (TGA), dynamic mechanical analysis (DMA) and three bend point tests. The PVOH-based molding compounds featured better mechanical properties than those based on EVA. Increasing the polymer content produced weaker but tougher molding compounds. Increasing wax content improved stiffness but resulted in a loss of toughness. The TG results showed that both compounds decomposed readily at elevated temperatures and left less than 3 wt.% ash at 800°C.

Thermo-mechanical Properties of Urea-based Pattern Molding Compounds for Investment Casting