Novel sprue designs in metal casting via 3D sand-printing

Sama, Santosh Reddy; Badamo, Tony; Lynch, Paul C.; Manogharan, Guha

doi:10.1016/j.addma.2018.12.009

Cited by 52 publications

(31 citation statements)

References 34 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…They are applied to build "ready-to-use" mechanical parts as well as tools (molds, dies, punches, etc.) [19,20]. Over the past few years, MAM methods have been used in the production of regular cellular structures [21][22][23][24] that demonstrate high energy absorption capacities with low relative densities [25][26][27][28].…”

Section: Introductionmentioning

confidence: 99%

Investigations on Mechanical Properties of Lattice Structures with Different Values of Relative Density Made from 316L by Selective Laser Melting (SLM)

Płatek¹,

Sienkiewicz²,

Janiszewski³

et al. 2020

Preprint

View full text Add to dashboard Cite

Nine variants of regular lattice structures with different relative densities have been designed and successfully manufactured. The produced structures have been subjected to geometrical quality control, and the manufacturability of the implemented selective laser melting SLM technique has been assessed. It was found that the dimensions of the produced lattice struts differ from those of the designed struts. These deviations depend on the direction of geometrical evaluation. Additionally, the microstructures and phase compositions of the obtained structures were characterized and compared with those of conventionally produced 316L stainless steel. The microstructure analysis and X-Ray Diffraction XRD patterns revealed a single austenite phase in the SLM samples. Both a certain broadening and a displacement of the austenite peaks were observed due to residual stresses and a crystallographic texture induced by the SLM process. Furthermore, the mechanical behavior of the lattice structure material has been defined. It was demonstrated that under both quasi-static and dynamic testing, lattice structures with high relative densities are stretch-dominated, whereas those with low relative densities are bending-dominated. Moreover, the linear relationship between the energy absorption and relative density under dynamic loading conditions has been defined

show abstract

Section: Introductionmentioning

confidence: 99%

Investigations on Mechanical Properties of Lattice Structures with Different Values of Relative Density Made from 316L by Selective Laser Melting (SLM)

Płatek¹,

Sienkiewicz²,

Janiszewski³

et al. 2020

Preprint

View full text Add to dashboard Cite

show abstract

“…The physics involved in 3DSP has been well researched [4,5], not only for optimizing the part performance [6], but also for enhancing casting performance by facilitating complex gating systems [7]. Complex gating systems including conical-helix sprue designs that can result in castings of significantly higher quality are now feasible via 3DSP [8,9]. The layer-by-layer fabrication process of 3DSP offers the ability to access the entire volume of the sand mold which offers the flexibility to embed foreign components into a priori-designed cavities to enable: (a) fabrication of smart molds by embedding sensors [4]; (b) enhancement of directional solidification by inserting chills similar to traditional casting techniques [10]; and (c) regulation of fluid flow by inserting filters [10] in otherwise difficult-to-access mold locations among other potential applications of embedded components.…”

Section: Introductionmentioning

confidence: 99%

“…Similarly, in aluminum [13] and magnesium alloys [14], agitation in liquid metal due to poor gating systems is reported to be a major cause for prevalent casting defects. Therefore, gating systems are often redesigned to mitigate turbulence through the use of techniques such as computational simulations [15]; numerical and statistical optimization [14,16,17]; and non-conventional gating systems [8]. However, real-time metal velocity in both traditional and 3DSP molds is currently unexplored.…”

Section: Introductionmentioning

confidence: 99%

Measurement of Metal Velocity in Sand Casting during Mold Filling

Sama

MacDonald

Voigt

et al. 2019

Metals

View full text Add to dashboard Cite

Melt turbulence during mold filling is detrimental to the quality of sand castings. In this research study, the authors present a novel method of embedding Internet of Things (IoT) sensors to monitor real-time melt flow velocity in sand molds during metal casting. Cavities are incorporated in sand molds to position the sensors with precise registration. Capacitive and magnetic sensors are embedded in the cavities where melt flow velocity is calculated by using an oscillator, the frequency of which is sensitive to changes in the close field permittivity, and change in magnetic flux, respectively. Their efficiency is investigated by integrating the sensors into 3D sand-printing (3DSP) molds for conical-helix and straight sprue configurations to measure flow velocities for aluminum alloy 319. Experimental melt flow velocities are within 5% of estimations from computational simulations. A major benefit of 3DSP is the geometrical freedom for complex gating systems necessary to reduce turbulence and access to mold volume for sensor integration during 3DSP processing. Findings from this study establish the opportunity of embedding IoT sensors in sand molds to monitor metal velocity in order to validate simulation results (2–5% error), compare gating systems performance, and improve foundry practice of manual pouring as a quality control system.

show abstract

“…A sprue that will curve into the runner was suggested by Sama and Manogharan [12]. They later developed a parabolic sprue [13], which performs satisfactorily but it requires the use of a 3D sand printing machine to produce it. However a filter positioned close to the sprue exit will cause the molten metal to enter the runner at the appropriate speed with a uniform front.…”

Section: Spruesmentioning

confidence: 99%

Untitled

2020

ETRJ

View full text Add to dashboard Cite

A recent study conducted by the authors, recording on site observations and grading responses to questionnaires by the 1 to 5 according to the Likert scale indicates that the gating practice in the foundries of research institutions and tertiary institutions in Lagos state is far from the best global practice. Some common errors, such as lack of knowledge and application of the critical flow velocity of the molten metal, prevention of flow stoppage across extensive horizontal planes with consequential non uniform liquid front. Lack of knowledge of the best types of pouring basins to use, Lack of knowledge on general filter types and usages among others were identified. This paper provides simple but highly effective solutions that do not warranty the purchase of new facilities. It is important to advance the knowledge of our training institutes especially as they are responsible for the training of our present and future foundry work force. The capability of our foundries is improved by the quality of the work force and this paper is hoped will contribute in no small measure to the capability of our foundries by improving the knowhow of the work force.

show abstract

Novel sprue designs in metal casting via 3D sand-printing

Cited by 52 publications

References 34 publications

Investigations on Mechanical Properties of Lattice Structures with Different Values of Relative Density Made from 316L by Selective Laser Melting (SLM)

Investigations on Mechanical Properties of Lattice Structures with Different Values of Relative Density Made from 316L by Selective Laser Melting (SLM)

Measurement of Metal Velocity in Sand Casting during Mold Filling

Untitled

Contact Info

Product

Resources

About