Evaluation of 3D-printed Pattern Material for Heat-hardened Inorganic Moulds Authors Kalle Jalava

• Autorzy: Jalava Kalle , Anwa Nurul , Orkas Juhani

Identyfikatory

DOI

10.7494/jcme.2024.8.2.25

• Języki publikacji: EN

Abstrakty

EN

Inorganic binders for sand moulding are currently of high interest due to the need to lessen our environmental impact and emissions. In this study, a heat hardened solid inorganic sodium silicate binder was tested with a 3D printed resin material to see how the use of such a material affected a silica mould’s quality, e.g. surface roughness. Results were compared to moulds made with metallic patterns. The unmodified binder had sticking issues when used with a metallic pattern, resulting in a rough as-moulded surface. Such issues were not seen with the printed resin patterns, also hinting at good performance with binders that contain performance increasing additives. The resin pattern material has a Heat Deflection Temperature (HDT) of 230°C, enabling the use of inorganic binders that require temperatures between 160–200°C to harden and dry. Additive manufacturing of such materials also allows designs for other hardening techniques than furnace heating, such as microwave heating. The moulds hardened with microwaves did not exhibit sticking issues. Additive manufacturing of tooling is a potential source of geometrical variation in final castings and are also studied in this work. In general, switching from traditional sand moulding patterns used with organic binder systems to inorganic systems, the patterns and core boxes need to be replaced by new ones made of a metallic or other heat resistant material. The studied material is a promising option for such a switch, especially when a complex shape enabled by additive manufacturing is also required.

Słowa kluczowe

EN

solid silicate; inorganic binder; additive manufacturing; patternmaking; heat hardening

• Wydawca: AGH University of Science and Technology Press
• Czasopismo: Journal of Casting & Materials Engineering
• Rocznik: 2024
• Tom: Vol. 8, no. 2
• Strony: 25--29
• Opis fizyczny: Bibliogr. 10 poz., il.

Twórcy

autor

Jalava Kalle

• Aalto University, Department of Mechanical Engineering, Puumiehenkuja 3, 02150 Espoo, Finland

• https://orcid.org/0000-0003-4882-6226

autor

Anwa Nurul

• Aalto University, Department of Mechanical Engineering, Puumiehenkuja 3, 02150 Espoo, Finland

• https://orcid.org/0000-0003-2187-6397

autor

Orkas Juhani

• Aalto University, Department of Mechanical Engineering, Puumiehenkuja 3, 02150 Espoo, Finland

• https://orcid.org/0000-0003-4159-7301

Bibliografia

• Miao H., Du X., Sun Y., Zhang M. & Song G. (2021). Effect of powder breakdown additives on properties of ester-hardened sodium silicate bonded ceramic sand. International Journal of Metalcasting, 15(2), 710–718. Doi: https://doi.org/10.1007/s40962-020-00517-z.
• Zaretskiy L. (2018). Hydrous solid silicates in new foundry binders. International Journal of Metalcasting, 12(2), 275–291. Doi: https://doi.org/10.1007/s40962-017-0155-6.
• Anwar N., Jalava K. & Orkas J. (2022). Experimental study of inorganic foundry sand binders for mold and cast quality. International Journal of Metalcasting, 17(3), 1697–1714. Doi: https://doi.org/10.1007/s40962-022-00897-4.
• Malachowska A., Stachowicz M. & Granat K. (2012). Innovative Microwave Hardening of Water-Glass Containing Sandmixes in Technical-Economic Approach. Archives of Foundry Engineering, 12(1), 75–80. Doi: https://doi.org/10.2478/v10266-012-0015-z.
• Granat K., Nowak D., Pigiel M., Stachowicz M. & Wikiera R. (2007). The influence of hardening method on basic properties of water glass molding sands. Visnik Chmel’nickogo Nacional’nogo Universitetu, 1(4), 98–104.
• Polzin H. (2014). Inorganic Binders: For Mould and Core Production in the Foundry. Schiele & Schön, Berlin.
• Ramakrishnan R., Griebel B., Volk W., Günther D. & Günther J. (2014). 3D printing of inorganic sand moulds for casting applications. Advanced Materials Research, 1018, 441–449. Doi: https://doi.org/10.4028/www.scientific.net/amr.1018.441.
• Zmarzły P., Kozior T. & Gogolewski D. (2019). Dimensional and shape accuracy of foundry patterns fabricated through photo-curing. Technical Gazette, 26(6), 1576–1584. Doi: https://doi.org/10.17559/TV-20181109115954.
• Brackett J., Yan Y., Cauthen D., Kishore V., Lindahl J., Smith T., Sudbury Z., Ning H., Kunc V. & Duty C. (2021). Characterizing material transitions in large-scale. Additive Manufacturing, 38. Doi: https://doi.org/10.1016/j.addma.2020.101750.
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Uwagi

Opracowanie rekordu ze środków MNiSW, umowa nr SONP/SP/546092/2022 w ramach programu "Społeczna odpowiedzialność nauki" - moduł: Popularyzacja nauki i promocja sportu (2024)