In furnaces with different heating elements, Nb-Si based ultrahigh-temperature alloy rods were re-melted in pure yttria mold shells and zirconia face-coat mold shells at 1850 • C for 30 min. The results evidenced that in the furnace with a tungsten heating element, the microstructure of the re-melted alloy became coarser, and the composition varied depending on the type of mold shell. Although the interface reaction layer between the re-melted alloy and the zirconia face-coat mold shell was much thicker, the deformability of the mold shell and the sand burning phenomenon of the alloy inside it were improved and ameliorated, respectively. However, after being re-melted in the furnace with a graphite heating element, the misrun phenomenon occurred in both specimens. Both re-melted alloys inside the mold shells were divided by a gap into an internal and an external part, with totally different microstructures and compositions. No reaction layer emerged at the interface between the re-melted alloy and the mold shells. Instead, infiltration zones arose in the mold shells adjacent to the interface.Metals 2019, 9, 721 2 of 15 coating in mold shells for investment casting of active and refractory metals. Especially, yttria has been successfully applied in the preparation of directionally solidified Nb-Si based ultrahigh-temperature alloys with a single orientation structure and high mechanical properties. As an example, Guo and Guo [11] performed integrally directional solidification of Nb-Si based ultrahigh-temperature alloys, in which yttria was employed as crucible material. Ma et al. [12] technically studied the interface interactions between Nb-Si-based ultrahigh-temperature alloys and pure yttria mold shells and found only a 5 to 15 µm-thick reaction layer composed of HfO 2 and Y 2 O 3 formed at the metal-mold shell interface. This further confirms that yttria is relatively inert to this alloy and is a qualified material for the mold shell during investment casting of this alloy. However, yttria is inclined to be hydrated with water, which leads to a significant loss of the life period of the as-prepared slurries as a result of gelatinization [13]. This ineluctably increases the overall technical costs of investment casting. On the contrary, it is not an issue for slurries filled by zirconia. However, in view of the substitution reaction between ZrO 2 and Hf, the application of zirconia on re-melting Nb-Si-based ultrahigh-temperature alloys is scarce. Nevertheless, the addition of Hf is becoming unnecessary, considering the impact of this element on the alloy, as reported recently [14]. It can be predicted that the content of Hf is likely to be reduced or replaced completely by other elements in the modified alloy. Hence, zirconia is also a potential mold shell material with practical application in confectioning this alloy.Besides the mold shell problems to be solved, the issues of the filling capability, microstructure homogeneity, element segregation, casting defects, and sand burning should all be evaluated fo...