Thermal and Structural Behavior of Investment Casting Molds Modified with Biodegradable Walnut Shell Chips

Two types of spherical mold samples—designated PW1 (reference) and PW2 (modified) were prepared using the dip-and-sprinkle method. Both samples consisted of seven layers, but PW2 was differentiated by the incorporation of 5 wt.% ground walnut shell chips into the fifth layer of its structure. The aim of this modification was to assess the feasibility of employing biodegradable organic additives to generate controlled porosity after thermal decomposition, thereby enhancing gas transport through the mold structure. The gas permeability of the samples was determined across a broad temperature range from 25 to 950 °C using a dedicated, custom-built test rig developed for elevated-temperature permeability assessments. The results revealed that the inclusion of walnut shell chips significantly increased the gas permeability of the molds by approximately 42% at ambient temperature and 36% at 950 °C, attributable to the formation of stochastically distributed macro-voids upon burnout of the organic additive. The study demonstrates that selective layer modification using natural waste materials can be a viable method for tailoring functional properties of ceramic molds, offering a cost-effective, sustainable, and easily scalable alternative to conventional pore-forming strategies.