Laser Sintering of Silica Sand ? Mechanism and Application to Sand Casting Mould

Wang, X. H.; Fuh, Jerry Ying Hsi; Wong, Yin Kwan; Tang, Yew Chung

doi:10.1007/s00170-002-1424-x

Cited by 36 publications

(12 citation statements)

References 5 publications

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“…The following two examples show the direct SLS process, and the relation between laser processing parameters and the surface roughness and dimensional accuracy of the sintered parts. Wang et al made use of a CO 2 laser to directly sinter silica sand, which is a mixture of SiO 2 (97.51 wt.%), with small amount of a variety of impurity of elements such as Zr, Ti, Ca, Al, Ba, Fe, Cs, Mg [11]. Pure silica softens at 1500 C and melts at 1600 C [11], but the impurities form a low-melting point eutectic that partially melts at 500-700 C. The existence of impurities Figure 11.…”

Section: Exemplar Ii: Silica (Sio 2 )mentioning

confidence: 99%

“…Sand mold built from silica sand powders, using LPBF. Reprinted from [11], with permission of Springer.…”

Section: Exemplar Ii: Silica (Sio 2 )mentioning

confidence: 99%

“…Among these, LPBF offers the opportunity for fast and direct fusion without costly post treatments and toxic binders which are often required by other techniques. LPBF-produced ceramic parts have potential to impact several applications such as medical and dental components [8][9][10], metal casting molds [11], thin wall structures, turbine blades, nozzles [12], and thermal or electrical insulation [13].…”

Section: Introductionmentioning

confidence: 99%

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Processing Parameters for Selective Laser Sintering or Melting of Oxide Ceramics

Zhang¹,

LeBlanc²

2018

Additive Manufacturing of High-Performance Metals and Alloys - Modeling and Optimization

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In this chapter, we present a detailed introduction to the factors which influence laser powder bed fusion (LPBF) on oxide ceramics. These factors can be in general divided in three main categories: laser-related factors (wavelength, power, scanning speed, hatch distance, scan pattern, beam diameter, etc.), powder-and material-related factors (flowability, size distribution, shape, powder deposition, thickness of deposited layers, etc.), and other factors (pre-or post-processing, inert gas atmosphere, etc.). The process parameters directly affect the amount of energy delivered to the surface of the thin layer and the energy density absorbed by the powders; therefore, decide the physical and mechanical properties of the built parts, such as relative density, porosity, surface roughness, dimensional accuracy, strength, etc. The parameter-property relation is hence reviewed for the most studied oxide ceramic materials, including families from alumina, silica, and some ceramic mixtures. Among those parameters, reducing temperature gradient which decreases the thermal stresses is one of the key factors to improve the ceramic quality. Although realizing crack-free ceramics combined with a smooth surface is still a major challenge, through optimizing the parameters, it is possible for LPBF processed ceramic parts to achieve properties close to those of conventionally produced ceramics.

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Section: Exemplar Ii: Silica (Sio 2 )mentioning

confidence: 99%

“…Sand mold built from silica sand powders, using LPBF. Reprinted from [11], with permission of Springer.…”

Section: Exemplar Ii: Silica (Sio 2 )mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Processing Parameters for Selective Laser Sintering or Melting of Oxide Ceramics

Zhang¹,

LeBlanc²

2018

Additive Manufacturing of High-Performance Metals and Alloys - Modeling and Optimization

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“…This was mainly due to the production method -i.e. selective laser sintered (SLS) sintered cores (Wang et al, 2003). They had very high resin content and this would cause high production rates of gases within the moulds resulting in poor quality castings -especially for aluminium, where the metal is susceptible to gas porosity (Snelling et al, 2013;Druschitz, Seals and Snelling, 2013).…”

Section: Foundry Issues With Printed Cores Compared To Traditional Momentioning

confidence: 99%

3D sand printing for automotive mass production applications

Wooldridge

Hackney

2017

IJRAPIDM

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Abstract:Additive manufacturing (AM) of metallic products is seen by many to be commercially viable for only small and highly complex components, manufactured with difficult to machine materials using heat sintering process. In the automotive manufacturing sector, metal hard tooling is often required to produce mass produced components, and the tools are typically bespoke, large in size, inflexible and complex. Conventionally these tools have either been machined from solid billets or near-net-shape cast and then machined to get final size. Rapid casting technologies (RCT) use AM 3D sand printing process to manufacture sand mould tools used to create the production tooling. Adopters of this technology can achieve an increasingly agile and robust production process, RCT can also rewrite the design hand book for casting design. The research findings demonstrate that RCT can be successfully applied within the automotive industry, achieving considerable cost and time savings whilst improving quality and product flexibility.Keywords: rapid casting technology; rapid tooling; 3D sand printing; sand casting.Reference to this paper should be made as follows: Hackney, P.M. and Wooldridge, R. (201X) '3D sand printing for automotive mass production applications', Int. J. Rapid Manufacturing, Vol. XX, No. YY, pp.XXX-XXX.Biographical notes: Philip M. Hackney is a senior member of the Department of Mechanical and Construction Engineering management team, managing several programmes both at Northumbria and Validated programmes at other HEI institutions worldwide. Hackney first started researching rapid prototyping in 1996, with the development of casting tools from the LOM process and later using the ZCast process awarded him a PhD in 2007, with over 30 published papers and a research group of 6 PhD students under his supervision. His current research interests include shop floor scheduling using genetic algorithms, additive manufacturing of polyurethane foams and sand printing of AM.Richard Wooldridge is currently a PT PhD Student at Northumbria University, following completing an MSc in Advanced Manufacturing Engineering at Loughborough University. He has developed and managed a major automotive Rapid Product Development Centre, at the forefront of commercialisation of industrial applications of AM, for over a decade.This paper is a revised and expanded version of a paper entitled [title] presented at [date/year and place where held].

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“…Among these technologies, the selective laser sintering (SLS) and 3D binder jetting printing (3DP) methods are becoming very attractive. These studies mainly focus on sand and binder materials, binder content, and mold properties, such as strength, permeability, gas release, and their influence on casting quality [6][7][8][9][10][11][12][13] . Combination of cores into a single one is also the benefit brought by 3D printing, with reduced stacking tolerances and improved dimensional accuracy [14,15] .…”

mentioning

confidence: 99%

Cooling control for castings by adopting skeletal sand mold design

et al. 2021

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Although many procedures are involved in casting production, the most important thing is the casting forming process in the molds. To control the cooling of castings in molds, the mold structure can be modified and molding materials can be properly selected. Chromite sand or zircon sand are usually used instead of silicon sand for the layer in contact with liquid metal for the making of large castings. Molds made of graphite and metals are also used in the casting industry, especially for dies which have long been used in the permanent mold casting and die casting, in which water cooling and oil heating channels are usually arranged [1,2]. In sand molds, pipes can be buried to circulate air or water or even liquid

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Laser Sintering of Silica Sand ? Mechanism and Application to Sand Casting Mould

Cited by 36 publications

References 5 publications

Processing Parameters for Selective Laser Sintering or Melting of Oxide Ceramics

Processing Parameters for Selective Laser Sintering or Melting of Oxide Ceramics

3D sand printing for automotive mass production applications

Cooling control for castings by adopting skeletal sand mold design

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