A s a near-net shape forming process, investment casting finds more and more applications because of the increasing focus on the quality of new products [1][2][3] ; therefore, the amount of shell waste produced is huge. As with the conventional casting process, the investment casting process will produce pollution and waste of resource materials if they are not properly disposed. A lot of attention has been paid to recycling the used sand in conventional casting, and some effective processes have been developed and applied, which, however, are not suitable for recycling investment casting shell waste. Compared with conventional casting, the shell waste has higher strength after shakeout because it experiences a more complex process during shell-making. To date, the complexity of recycling the waste inhibits the development of investment casting [4][5][6][7] . Thus, developing new approaches of recycling the investment casting ceramic shell waste is of great significance.Extensive investigations on recycling the used shell from investment casting have been conducted by Zhao, et al [8][9][10][11] . The recycled materials were reused as the back sand for making new shells in investment casting, or Abstract: In the present study, a processing technique for recycling investment casting ceramic shell waste was proposed to separate valuable refractory aggregate zircon sand. The microstructure and phase constituents of the shell waste and separation process were investigated. The results show that the characteristics of microstructure and phase constituents of the shell waste can meet the conditions for preferentially separating zircon sand, and zircon sand can be separated by gravity separation on a shaking table. The separated zircon sand has good shape and high purity, and can be used for the production of castings and other applications.
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