Simulation of transient thermal stress in gypsum-bonded investment.

The aim of this study was to clarify the effect of heating rate on the development of both transient and residual stresses in investment molds. Solid, cylindrical, gypsum-based molds were modeled and theoretical calculations made of temperature distributions with a constant heating rate. These calculations used experimental thermal diffusivity data obtained with a laser flash method. The simulations calculated transient thermal stresses during heating and at the end of heating for two surface conditions: an unrestricted surface, and a surface restricted by a casting ring. The simulation model developed nonuniform strains and stresses at casting temperature; tangential stress was compressive at the surface and tensile at the mid-point for the unrestricted surface model. The surface restricted model developed compressive tangential stresses throughout the mold at the casting temperature. This resulted in significant thermal strain differences compared to the magnitudes of expansion of the mold due to heating.