Effects on the investment casting of yellow gold
Silicon as a small addition in casting alloys has (like zinc) some
beneficial effects in casting alloys. The effects are:
Increased the form-filling
Reduced reaction with investment
Brighter the surface in the as-cast state
Reduced surface roughness
The reason is probably similar to that given for zinc additions: A reduced interfacial tension is responsible for the increase of 'fluidity' and the formation of a dense, colourless oxide layer results in the brighter surface in the as-cast state. Thus, the melt can more easily fill thin cavaties and reproduce the smooth surface of the pattern. As with zinc, the reaction with investment might be reduced too.
Side effects
Silicon, as an addition to carat golds, has two serious side effects:
a) Embrittlement of the alloys by formation of low melting brittle phases segregated on grain boundaries.
b) Production of a very large grain size, further increasing the danger of fracture.
As has been already discussed, silicon is only soluble in the alloys to a very limited extent. Any surplus silicon in excess of this solubility causes brittle fracture, as seen in Figures 5 and 6. This 'disease' is the origin of numerous rejects in jewellery manufacture.
Silicon is also one of the most effective grain coarseners. The coarse (large) grain size favours not only fracture, especially if small amounts of a low melting silicon compound are present, but acts also detrimentally to the polishing behaviour. A grain refining addition is inevitably necessary if silicon additions are to be used in practice. However, according to McCloskey et al (12), silicon may form silicides with many grain refiners. The grain refining effect is extinguished and hard inclusions are formed. In spite of this result, iridium is sometimes used as a grain refiner in practice.
Recommendations for application
Without doubt, silicon is a very effective addition for increasing 'fluidity' of the melt with consequent improved form-filling and surface quality. It also produces a very bright surface on cast items. Many commercial master alloys and carat golds contain silicon additions. On the other hand, serious detrimental side effects can occur, as described above, which increase the manufacturing reject rate drastically. It should be used only with care in an amount which is well adapted to the composition of the base alloy. Due to the reducing maximum addition with increasing gold content, the use of silicon in high (21, 22 ct) carat golds is not advised.