Evaluation of additive manufacturing of sand cores in terms of the resulting surface roughness

Gawronová, Martina; Lichý, Petr; Kroupová, Ivana; Obzina, Tomáš; Beňo, Jaroslav; Nguyenová, Isabel; Merta, Václav; Jezierski, J.; Radkovský, Filip

doi:10.1016/j.heliyon.2022.e10751

Cited by 10 publications

(3 citation statements)

References 37 publications

(53 reference statements)

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“…The manufacture of molds and cores using 3D sand printing is of great interest, as evidenced by the growing number of publications devoted to the subject [23][24][25][26]. One of the most important advantages is the virtually unlimited possibilities regarding the shape of cores, as well as the high precision of printing.…”

Section: Introductionmentioning

confidence: 99%

3D Printed (Binder Jetting) Furan Molding and Core Sands—Thermal Deformation, Mechanical and Technological Properties

et al. 2023

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Casting cores produced in additive manufacturing are more often used in industrial practice, in particular in the case of the production of unit castings and castings with very complex geometry. The growing interest in the technology of 3D printing of cores and molds also brings emerging doubts related to their mechanical and technological properties. This article presents a comparison of the properties of cores made of sand with acid-curing furfuryl resin, made with 3D printing technology; the cores were prepared in a conventional way (mixing and compaction). The main purpose of this research was to determine the possibility of using shell cores as a substitute for solid cores, aimed at reducing the amount of binder in the core. The influence of the type of the binder and the size of the grain matrix fraction on the obtained mechanical and technological properties of the cores, with particular emphasis on abrasion and thermal deformation, as well as on the kinetics of their hardening, was demonstrated.

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Section: Introductionmentioning

confidence: 99%

3D Printed (Binder Jetting) Furan Molding and Core Sands—Thermal Deformation, Mechanical and Technological Properties

et al. 2023

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“…Binder jetting is a powerful additive manufacturing method, and many companies are interested in this technology (ExOne, 2018; Boström and Amnebrink, 2020; voxeljet, 2022). Binder jetting is mainly used to manufacture sand molds (Le Néel et al , 2018; Gawronová et al , 2022). All powdered materials can be used in binder jetting.…”

Section: Introductionmentioning

confidence: 99%

Using adaptive slicing method and variable binder amount algorithm in binder jetting

Baş

Yapıcı

Inanc

2023

RPJ

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Purpose Binder jetting is one of the essential additive manufacturing methods because it is cost-effective, has no thermal stress problems and has a wide range of different materials. Using binder jetting technology in the industry is becoming more common recently. However, it has disadvantages compared to traditional manufacturing methods regarding speed. This study aims to increase the manufacturing speed of binder jetting. Design/methodology/approach This study used adaptive slicing to increase the manufacturing speed of binder jetting. In addition, a variable binder amount algorithm has been developed to use adaptive slicing efficiently. Quarter-spherical shaped samples were manufactured using a variable binder amount algorithm and adaptive slicing method. Findings Samples were sintered at 1250°C for 2 h with 10°C/min heating and cooling ramp. Scanning electron microscope analysis, surface roughness tests, and density calculations were done. According to the results obtained from the analyzes, similar surface quality is achieved by using 38% fewer layers than uniform slicing. Research limitations/implications More work is needed to implement adaptive slicing to binder jetting. Because the software of commercial printers is very difficult to modify, an open-source printer was used. For this reason, it can be challenging to produce perfect samples. However, a good start has been made in this area. Originality/value To the best of the authors’ knowledge, the actual use of adaptive slicing in binder jetting was applied for the first time in this study. A variable binder amount algorithm has been developed to implement adaptive slicing in binder jetting.

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“…This feature facilitates effective heating and cooling of these molds and cores. The 3D printing process, which involves applying successive layers of resin onto the previously coated binder grains, allows for the formation of micro-pores that facilitate the free flow of heat and achieve optimal casting properties by reducing shrinkage and minimizing thermal stresses during solidification [12][13][14].…”

Section: Introductionmentioning

confidence: 99%

The Influence of 3D Printing Core Construction (Binder Jetting) on the Amount of Generated Gases in the Environmental and Technological Aspect

Bobrowski,

Woźniak,

Żymankowska-Kumon

et al. 2023

Materials

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This article presents the findings of a study focusing on the gas generation of 3D-printed cores fabricated using binder-jetting technology with furfuryl resin. The research aimed to compare gas emission levels, where the volume generated during the thermal degradation of the binder significantly impacts the propensity for gaseous defects in foundries. The study also investigated the influence of the binder type (conventional vs. 3D-printed dedicated binder) and core construction (shell core) on the quantity of gaseous products from the BTEX group formed during the pouring of liquid foundry metal into the cores. The results revealed that the emitted gas volume during the thermal decomposition of the organic binder depended on the core sand components and binder type. Cores produced using conventional methods emitted the least gases due to lower binder content. Increasing Kaltharz U404 resin to 1.5 parts by weight resulted in a 37% rise in gas volume and 27% higher benzene emission. Adopting shell cores reduced gas volume by over 20% (retaining sand with hardener) and 30% (removing sand with hardener), presenting an eco-friendly solution with reduced benzene emissions and core production costs. Shell cores facilitated the quicker removal of gaseous binder decomposition products, reducing the likelihood of casting defects. The disparity in benzene emissions between 3D-printed and vibratory-mixed solid cores is attributed to the sample preparation process, wherein 3D printing ensured greater uniformity.

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Evaluation of additive manufacturing of sand cores in terms of the resulting surface roughness

Cited by 10 publications

References 37 publications

3D Printed (Binder Jetting) Furan Molding and Core Sands—Thermal Deformation, Mechanical and Technological Properties

3D Printed (Binder Jetting) Furan Molding and Core Sands—Thermal Deformation, Mechanical and Technological Properties

Using adaptive slicing method and variable binder amount algorithm in binder jetting

The Influence of 3D Printing Core Construction (Binder Jetting) on the Amount of Generated Gases in the Environmental and Technological Aspect

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