Accelerating advancements in technological systems have demonstrated a need for alloys with drastically improved thermomechanical and chemical properties, called superalloys. Ceramic molds are typically used in near-net shape investment casting processes of superalloy components due to their chemical inertness and high-temperature capabilities. Ceramic molds, however, often suffer from shortcomings in vital properties including flexural strength, thermal shock resistance, permeability, dimensional stability, corrosion resistance, and leachability, which have restricted their ability to adequately process modern alloy castings. This study analyses these limitations and illustrates how to address them, particularly regarding ceramic mold and slurry design, processing of shells and cores, material selection, and testing and characterization. By utilizing advanced processing methods including additive manufacturing and gel-casting, more dimensionally accurate and preferentially built molds can be formed. Additionally, by varying the mold composition to achieve more chemically inert structures, reactions with the mold can be mitigated to reduce chemically induced defects.


Materials Science and Engineering


University of Connecticut, Grant None

Keywords and Phrases

Ceramic core; Characterization; Investment casting; Nickel superalloys; Refractories

International Standard Serial Number (ISSN)

1873-619X; 0955-2219

Document Type

Article - Journal

Document Version


File Type





© 2023 Elsevier, All rights reserved.

Publication Date

01 Dec 2020