What is Mercast Process - Applications, Advantages and Disadvantages of Mercast

liquid mercury pouring

Mercasting / mercast process is an improvement in precision investment casting. In this manufacturing process, the pattern is made of mercury is used to make mould. The mercury pattern is formed in a special aluminium mould. At normal room temperature, the mercury is filled into the master mould. Then the whole unit is cooled to a temperature below -38°C, eventually the mercury gets solidify. The frozen mercury pattern is then removed from the master mould and dipped into series of special slurries to form a harder ceramic shell around them.

The temperature the mercury then allow to rise, the liquefied mercury then retrieved from mould. The obtained mould is then used for investment casting.

- Types of pattern materials
Types of Pattern Allowance and Its Reason

Advantages and applications of mercast

  • Excellent quality. It gives better surface finish.
  • Mercury did not expand when it changed from solid form to liquid form. So there is no any unwanted stress inside the mould during pattern removal by melting.
  • Mercury can flow into very thin sections of the master mould, hence form a very detailed pattern.
  • It gives close tolerance. Usually the mercasted shape does not need further finishing process.
  • The mercury can be reused to making the Pattern again.

Disadvantages of mercast

  • Mercast process is expensive
  • Pattern must be kept at low temperature; it is not desirable in common foundry operation.
  • Mercury is hazardous to health.
  • Time-consuming process.

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