Optimizing the fluidity in thin-section investment casting for vacuum induction molten AZ91D-1 wt.% CaO

• Thin-section AZ91D-1 %wtCaO fluidity optimized for biomedical device casting. • Vacuum in induction melting increases oxidation, impairing thin-section filling. • Yttria coating reduces fluidity due to crack-induced flow obstruction. • Best fluidity achieved without vacuum and coatings in thin-section casting. This paper discusses an experimental investigation into the fluidity of AZ91D-1 %wt. CaO magnesium melt via induction for thin-section investment casting. Plaster molds with thin spiral cavities (0.5 to 1.5 mm square sections) were designed and manufactured to assess the impact of casting conditions on filling length, as magnesium alloys cause severe melting and melt-mold exothermic reactions, making investment casting challenging. Combinations of traditional Mg-mold reaction mitigation techniques, such as applying a protective mold coating (Yttria) and vacuum, were examined to determine their role in the filling process. The results suggest that when induction is employed to melt reactive alloys, these methods are not always beneficial, as initially thought. Particularly at higher melt temperatures, the combination of Yttria-coated molds with low-pressure vacuum induction significantly reduce fluidity: vacuum induced melt levitation which promotes oxidation with the residual atmosphere; and Yttria-coating cracking due to thermal stress during the mold fabrication slows filling and promotes significant melt-mold reaction. This study shows that best results to investment cast thin-sections are obtained by avoiding both vacuum and protective coatings, providing a viable route for the precision manufacturing of stent biomedical devices.