Archives of Foundry Engineering

Conventional means of producing material via metal casting have long been used for centuries. In spite of its advantages in producing durable parts with lower cost implications and the accommodation of large part production, this conventional approach is still characterized by the challenges of high lead time in patterns production, poor surface finish, and the need for secondary manufacturing operations, which always leads to material loss. Hence, the introduction of additive manufacturing (AM) to metal casting process has been immensely recognized because of its huge advantages in negating some of the challenges encountered in the conventional route. However, the inconsistency in the material properties (such as density, strength, elastic modulus, dimensional accuracies, surface finish), produced by one of the AM techniques (rapid sand casting), has not been yielding optimum results to be applied in high-tech application like aerospace and automotive industries. Furthermore, this technique lacks efficient qualification and certification, which contributes to their disadvantages. This review focuses on the challenges and recent progress in producing parts from rapid sand moulds and cores via binder jetting (BJ), as well as the need to incorporate efficient qualification and certification in the future production of parts from rapid sand casting.

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Experimental Study of Inorganic Foundry Sand Binders for Mold and Cast Quality

Anwar

Jalava

Orkas

2022

Inter Metalcast

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The interest in inorganic foundry binders has been rising steadily in recent times due to their favorable environmental characteristics. This paper compares the mold quality and cast quality attained with different inorganic binders. Three different types of sand and five different inorganic binders were used for the mold quality study. Of the inorganic binders, there was liquid sodium silicate used in different hardening methods, a geopolymer binder, and also solid sodium silicate. The mold quality was assessed through bending strength, residual bending strength, tensile strength, and loss on ignition measurement. A total of 12 castings were made using molds of different binders and sand materials. The cast quality was then assessed by tracking changes in dimension and the surface quality of final castings. Inorganic binders performed well in terms of mold strength and very well in terms of loss on ignition but there is room for improvement in the surface quality of the castings attained.

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Archives of Foundry Engineering

Cited by 10 publications

References 7 publications

Other Molding and Core Sands with Inorganic Binders

Other Molding and Core Sands with Inorganic Binders

Challenges and recent progress on the application of rapid sand casting for part production: a review

Experimental Study of Inorganic Foundry Sand Binders for Mold and Cast Quality

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