Cast Iron Parts Obtained in Ceramic Molds Produced by Binder Jetting 3D Printing—Morphological and Mechanical Characterization

Abstract

Mechanical behavior and characteristics of two different types of materials: cast iron with lamellar graphite EN-GJL-250 and cast iron with spheroidal graphite EN-GJS-400-15 which were cast in ceramic molds using gravitational casting method has considered in this research. The ceramic molds were obtained by 3D printing method. First, a finite element analysis was developed to determine Tresca and von Mises stresses and the deformations of the ceramic molds under an applied pressure of 25 MPa. Samples were produced by gravitational casting using two types of cast iron materials. Mechanical tests were made using samples produced from these two types of materials and microstructure analysis evaluation of fractured zones was realized by scanning electron microscopy. Obtained results were finally used for designing, developing, and producing of one ‘hydraulic block’ of a railway installation by the Benninger Guss company of Switzerland.

Advances in Metal Casting Technology: A Review of State of the Art, Challenges and Trends—Part II: Technologies New and Revived

“…Realizing such alternative binder systems would mirror developments in conventional sand casting, where aluminum foundries have, in many cases, already adopted inorganic binder systems [216] and new solutions are becoming available that are also suited for iron and steel [217,218]. The challenge has in fact been taken up already by the respective industries, with the result that printable inorganic binders are available commercially for the casting of light alloys [215,219], while others suitable for the casting of higher melting materials are either under development [220] or are currently being evaluated on a semi-commercial basis. The chemistry of such inorganic binders is typically based on alkali-silicates or waterglass.…”