Process Development for Manufacturing of Cellular Structures with Controlled Geometry and Properties

Pinto, Paulo; Peixinho, Nuno; Soares, Delfim; Silva, Filipe

doi:10.1590/1516-1439.286614

Cited by 6 publications

(4 citation statements)

References 8 publications

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“…Fluidity, in turn, depends upon many factors related to the molten metal, mould, metal/mould interface etc. 40,41 , making synchronization a challenge when manual pouring is used. Furthermore, heat transfer between ingot, mould and environment should be sufficient to prevent excessive grain growth and allow a sufficiently thick, solid shell to form and the mushy zone (where solid and liquid coexist in the solidifying ingot) to develop a substantial coherent volume, i.e., a solid matrix substantial enough to bear the extraction load [42][43][44] .…”

Section: Methodsmentioning

confidence: 99%

A Continuous Casting Device with Electromagnetic Stirring for Production of SSM Feedstock Using Al-Si Alloys

2021

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This work describes the design, construction and testing of a continuous casting device coupled to an electromagnetic stirring system for the production of thixoforming feedstock using Al-Si alloys. The following processing and construction parameters were tested: pouring temperature (660-800 °C), mould cavity roughness (Ra = 0.17-1.06 µm), casting speed (2-4 mm/s), use of a combined (primary and secondary) cooling system and the intensity and radial penetration of electromagnetic stirring (0, 1500 and 3000 W stator power). The macro-appearance of the ingots and the longitudinal and radial microstructural parameters were then evaluated. The results indicate that the surface finish of the mould cavity was an important construction parameter as it had a strong influence on heat transfer and, consequently, feed speed; use of a secondary cooling system for the mould allowed greater grain refinement and microstructural homogeneity to be achieved for all the conditions tested; optimal electromagnetic stirring power was 1500 W (EMF max = 22 Gauss); this resulted in a grain size-todendritic arm spacing ratio of close to 1, which is suitable for subsequent SSM processing.

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Section: Methodsmentioning

confidence: 99%

A Continuous Casting Device with Electromagnetic Stirring for Production of SSM Feedstock Using Al-Si Alloys

2021

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“…Many printing techniques have been employed to fabricate polymer components, and although it is possible to find 3D printing of metals that creates parts directly through processes like laser-based, electron-beam-based, arc-based, and ultrasonic welding-based, they are processes considered high cost, both for the equipment and the materials and energy requirements needed [25,26]. Nevertheless, it is also possible to obtain polymeric models to use as a lost model in precision casting as has been reported by some authors [27][28][29].…”

Section: Introductionmentioning

confidence: 99%

Replication casting and additive manufacturing for fabrication of cellular aluminum with periodic topology: optimization by CFD simulation

Fernández‐Morales

Echeverri

Fandiño

et al. 2023

Int J Adv Manuf Technol

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In this work, processes such as additive digital manufacturing (ADM) and precision casting are presented as alternative methods to manufacture aluminum foams with ordered open-pore morphology. Digital modeling of cellular structures with defined regular patterns was manufactured with ABS and wax and then melted in aluminum A356 alloy by a replication casting process. To guarantee the complete filling of the mold, a simulation by the Flow-3D program was made. This computational tool allowed to determine the temperature values of both melting and the mold temperature. The simulations revealed potential defects in the metal foams to be obtained, which were evidenced by the cast pieces processed after as a validation test. The results show that the casting process carried out supported by a computational fluid dynamics (CFD) simulation allows understanding the effects of the simulated parameter process, optimizing the parameters involved in the infiltration process, and establishing the conditions for obtaining a sound piece of open-cell aluminum foam with truncated octahedron pores shape. The established manufacturing process conditions can be used to produce lattice structures with multifunctional uses such as impact and blast-proof devices, vibration attenuators, or where enhancement of heat transfer could be needed.

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“…Regarding the indirect additive manufacturing technique, a preform (an anti-structure of the designed porous structure) is prepared through the additive manufacturing process, and then the preform is combined with conventional processes to prepare the designed porous structure. Pinto et al [30,31] and Mun et al [32] successfully fabricated ordered porous aluminum with lower angular struts using a lost wax casting process, demonstrating that indirect additive manufacturing processes can escape the limitations of design angles for the preparation of ordered porous structures. [33] Furthermore, this process presented the advantages of good manufacturability, a wide range of material options, no residual stress in the specimen, and low cost.…”

Section: Introductionmentioning

confidence: 99%

Effect of Aluminum Porous Filling Methods on Mechanical Properties of Ordered– Disordered Porous Composite Structures

Bai

Liu

et al. 2022

Adv Eng Mater

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Herein, ordered porous aluminum is prepared using an indirect additive manufacturing method combining selective laser sintering (SLS) and infiltration casting process. Ordered porous aluminum samples with pore sizes of 7, 9, and 11 mm are prepared by varying the structure of the preforms. The pores of three types of ordered porous aluminum are filled with conventional disordered aluminum foam. Besides, ordered–disordered porous aluminum composite structures with two filling methods are designed and prepared. Afterward, the quasi‐static compression test is conducted on the sample, and the microscopic analysis is performed on the compressed sample. The compression and energy absorption properties of the ordered–disordered porous composite structure are investigated according to the test results. The increasing amount of disordered aluminum foam suppresses the deformation. The effect of the filling method on the compressive properties of the samples changes as the pore size varied. Compared with the ordered porous structures, ordered–disordered porous composite structures demonstrate higher compressive strength and energy absorption capacity with significantly higher platform stress.

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Process Development for Manufacturing of Cellular Structures with Controlled Geometry and Properties

Cited by 6 publications

References 8 publications

A Continuous Casting Device with Electromagnetic Stirring for Production of SSM Feedstock Using Al-Si Alloys

A Continuous Casting Device with Electromagnetic Stirring for Production of SSM Feedstock Using Al-Si Alloys

Replication casting and additive manufacturing for fabrication of cellular aluminum with periodic topology: optimization by CFD simulation

Effect of Aluminum Porous Filling Methods on Mechanical Properties of Ordered– Disordered Porous Composite Structures

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