Study on the Mechanical Properties of 3D-Printed Sand Mold Specimens with Complex Hollow Structures.

Casting, as a fundamental process in metal forming, finds widespread applications in the manufacturing industry. The advent of 3D printing hollow sand mold technology presents a novel method for casting technology to revolutionize traditional dense sand molds, offering increased flexibility in achieving quality control and improvement in casting processes. Consequently, this study delves into an examination of the mechanical strengths of 3D-printed sand molds with complex hollow structures and further investigates the influence of hollow sand mold concession on castings. The results indicate that compressive and high-temperature residual tensile and bending strengths vary in hollow structures. Multi-layer shells have greater high-temperature residual tensile, compressive, and bending strengths than truss hollow sand molds with roughly the same hollow volume fraction. Compared to dense sand molds, hollow sand molds, which have a lower mechanical strength, have better retractability, which helps reduce the residual stress and crack tendency of castings. The breaking of hollow structures is limited to local areas, unlike the penetrative cracking of dense sand molds. The I-beam-shaped casting test results indicate that a hollow structure is beneficial for the preservation of the integrity of a sand mold during the casting process. Compared to dense and truss hollow molds, a multi-layer shell hollow sand structure has the comprehensive advantages that it improves retractability while maintaining strength relatively well, reduces the residual stress, and avoids cracks in castings and itself.

Study on the Gas Release of 3D-Printed Furan Resin Sand Core during the Casting Process.

In sand casting, gas porosity is a common defect that can result in decreased strength, leakage, rough surfaces, or other problems. Although the forming mechanism is very complicated, gas release from sand cores is often a significant contributor to the formation of gas porosity defects. Therefore, studying the gas release behavior of sand cores is crucial to solving this problem. Current research on the gas release behavior of sand cores mainly focuses on parameters such as gas permeability and gas generation properties, through experimental measurement and numerical simulation methods. However, accurately reflecting the gas generation situation in the actual casting process is difficult, and there are certain limitations. To achieve the actual casting condition, a sand core was designed and enclosed inside a casting. The core print was extended to the sand mold surface, with two types of core prints: hollow and dense. Pressure and airflow speed sensors were installed on the exposed surface of the core print to investigate the burn-off of the binder of the 3D-printed furan resin quartz sand cores. The experimental results showed that the gas generation rate was high in the initial stage of the burn-off process. The gas pressure quickly reached its peak in the initial stage and then decreased rapidly. The exhaust speed of the dense type of core print was 1 m/s, lasting for 500 s. The pressure peak of the hollow-type sand core was 1.09 kPa, and the exhaust speed peak was 1.89 m/s. The binder can be sufficiently burned off for the location surrounding the casting and the crack-affected area, so the burnt sand appears white, while the burnt core appears black due to insufficient burning of the binder because of isolation from the air. The gas generated by the burnt resin sand in contact with air was 30.7% less than that generated by the burnt resin sand insulated from the air.

3D Phase Field Modeling of Multi-Dendrites Evolution in Solidification and Validation by Synchrotron X-ray Tomography.

In this paper, the dynamics of multi-dendrite concurrent growth and coarsening of an Al-15 wt.% Cu alloy was studied using a highly computationally efficient 3D phase field model and real-time synchrotron X-ray micro-tomography. High fidelity multi-dendrite simulations were achieved and the results were compared directly with the time-evolved tomography datasets to quantify the relative importance of multi-dendritic growth and coarsening. Coarsening mechanisms under different solidification conditions were further elucidated. The dominant coarsening mechanisms change from small arm melting and interdendritic groove advancement to coalescence when the solid volume fraction approaches ~0.70. Both tomography experiments and phase field simulations indicated that multi-dendrite coarsening obeys the classical Lifshitz-Slyozov-Wagner theory Rn-R0n = kc(t-t0), but with a higher constant of n = 4.3.

Study on the Directional Solidification Process of an Aluminum Alloy Bar in Multishell Mold Being Gradually Immersed in Water.

A multishell mold structure and water-immersion cooling method (MSMWI) is proposed for the directional solidification of castings. A four-layer-shell sand mold was designed for a bar with diameter of 40 mm. As the aluminum melt was poured, the multishell mold was gradually immersed in water, and the water level drove the advancement of the solidification front from bottom to top. The multishell mold was helpful for the heat insulation of its upper part, and its bottom was chilled by the water. Therefore, directional solidification of the bar was vertically realized. The water-cooled solidification process of the bar was 5.8 times faster than that by air natural cooling (MSMNC), and the temperature gradient was increased by 78 times. The secondary dendrite arm spacing (SDAS) and eutectic silicon were significantly refined. Its tensile strength, elongation, and hardness were increased by 56%, 185%, and 62.6%, respectively.

Modeling and Simulation of the Casting Process with Skeletal Sand Mold.

The author-proposed skeletal sand mold, which mainly includes a shell, air cavities and a truss support structure, has been experimentally proven to be very useful in controlling the cooling of casting at local areas and at different periods of the casting process. The modeling and simulation of the casting process using a skeletal sand mold were systemically analyzed. Complicated casting/mold and mold/air boundaries, and the thermal and mechanical behavior of the skeletal sand mold during the casting process were highlighted. A numerical simulation of the casting process of a stress frame specimen using a skeletal sand mold was performed. The temperature, stress and displacement fields of the casting and skeletal sand mold were obtained and compared with those using a traditional sand mold. The simulated results were validated with experiments. Using the skeletal sand mold, the cooling rate of the casting can be greatly improved due to the significant heat release from mold surface to environment. The residual stress and deformation of the casting can be reduced because of the decreased stiffness of this kind of mold. Although the skeletal sand mold is susceptible to cracking, it can be avoided by filleting in the conjunctions and increasing the shell thickness.

Effect of Layer-Wise Varying Parameters on the Microstructure and Soundness of Selective Laser Melted INCONEL 718 Alloy.

Selective laser melting (SLM) is a promising powder bed fusion additive manufacturing technique for metal part fabrication. In this paper, varying scanning speed in the range of 500 mm/s to 1900 mm/s, and laser power in the range of 100 W to 200 W, were realized from layer to layer in a cycle of 56 layers in a single cuboid Inconel 718 alloy specimen through SLM. Layer-wise variation of microstructure and porosity were acquired, showing the layer-wise controlling capability of microstructural soundness. The melt pool size and soundness are closely linked with the energy input. High energy density led to sound regions with larger, orderly stacked melt pools and columnar grains, while low energy density resulted in porous regions with smaller, mismatched melt pools, un-melted powder, and equiaxed grains with finer dendrites. With the increase of laser energy density, the specimen shifts from porous region to sound region within several layers.

A Study on the Effect of Ultrasonic Treatment on the Microstructure of Sn-30 wt.% Bi Alloy.

The effect of ultrasonic treatment on the microstructure of Sn-30 wt.% Bi alloy was studied at different temperatures. Results showed that the ultrasonic treatment could effectively refine the microstructure of Sn-30 wt.% Bi alloy at a temperature range between the liquidus and solidus. Application of the ultrasound could fragment the primary Sn dendrites during solidification due to a mixed effect of ultrasonic cavitation and acoustic streaming. The divorced eutectic formed when the ultrasonic treatment was applied for the whole duration of the solidification. The eutectic phase grew and surrounded the primary Sn dendrite, and pure Bi phase grew in between the Sn dendritic fragments. The mechanism of the fragmentation of dendrites and the divorced eutectic structure by ultrasonic treatment was discussed.

Effect of Scanning Routes on the Stress and Deformation of Overhang Structures Fabricated by SLM.

Selective laser melting (SLM) is a promising manufacturing method for the construction of complicated precision parts. However, deformation of the overhang during the fabrication process and post treatment is still a common problem. In this paper, the effect of the scanning route on the residual stress and deformation of fabricated AlSi10Mg overhang specimens by SLM was investigated. Different scanning routes for the overhang including longitudinal direction, transverse direction, and the alternation between these two scanning routes in consecutive layers were studied by experiments within this study. Numerical simulation was utilized to measure the stress of the specimens while deformation prediction was used for the different scanning routes. Both the experimental and simulated results showed that the scanning route had a substantial influence on the residual stress and deformation of the specimens. The longitudinal scanning resulted in significant upward bending deformation of the overhang as it was cut from the baseplate. However, there was less deformation for the overhangs fabricated by transverse and alternating scanning routes. A transverse scanning route is helpful for the reduction of residual stress in the longitudinal direction and the corresponding deformation.

Study on the Selective Laser Melting of CuSn10 Powder.

The selective laser melting of tin bronze (CuSn10) powder was performed with a laser energy density intensity level at 210, 220, and 230 J/mm². The composition was homogeneous with almost all tin dissolved into the matrix. The grain size of the obtained alpha copper phase was around 5 μm. The best properties were achieved at 220 J/mm² laser energy density with a density of 8.82 g/cm³, hardness of 78.2 HRB (Rockwell Hardness measured on the B scale), yield strength of 399 MPa, tensile strength of 490 MPa, and an elongation that reached 19%. “Balling effect” appeared and resulted into a decrease of properties when the laser energy density increased to 230 J/mm².

The Design of 3D-Printed Lattice-Reinforced Thickness-Varying Shell Molds for Castings.

3D printing technologies have been used gradually for the fabrication of sand molds and cores for castings, even though these molds and cores are dense structures. In this paper, a generation method for lattice-reinforced thickness-varying shell molds is proposed and presented. The first step is the discretization of the STL (Stereo Lithography) model of a casting into finite difference meshes. After this, a shell is formed by surrounding the casting with varying thickness, which is roughly proportional to the surface temperature distribution of the casting that is acquired by virtually cooling it in the environment. A regular lattice is subsequently constructed to support the shell. The outside surface of the shell and lattice in the cubic mesh format is then converted to STL format to serve as the external surface of the new shell mold. The internal surface of the new mold is the casting's surface with the normals of all of the triangles in STL format reversed. Experimental verification was performed on an Al alloy wheel hub casting. Its lattice-reinforced thickness-varying shell mold was generated by the proposed method and fabricated by the binder jetting 3D printing. The poured wheel hub casting was sound and of good surface smoothness. The cooling rate of the wheel hub casting was greatly increased due to the shell mold structure. This lattice-reinforced thickness-varying shell mold generation method is of great significance for mold design for castings to achieve cooling control.

The effect of ultrasonic processing on solidification microstructure and heat transfer in stainless steel melt.

The heat transfer in the ultrasonic processing of stainless steel melt is studied in this thesis. The temperature field is simulated when the metal melt is treated with and without ultrasound. In order to avoid the erosion of high temperature melt, ultrasound was introduced from the bottom of melt. It is found that the temperature of melt apparently increases when processed with ultrasound, and the greater the ultrasonic power is, the higher the melt temperature will be; ultrasonic processing can reduce the temperature gradient, leading to more uniform temperature distribution in the melt. The solidification speed is obviously brought down due to the introduction of ultrasound during solidification, with the increasing of ultrasonic power, the melt temperature rises and the solidification speed decreases; as without ultrasound, the interface of solid and mushy zone is arc-shaped, so is the interface of liquid and mushy zone, with ultrasound, the interface of solid and mushy zone is still arc-shaped, but the interface of liquid and mushy zone is almost flat. The simulation results of temperature field are verified in experiment, which also indicates that the dendrite growth direction is in accord with thermal flux direction. The effect of ultrasonic treatment, which improves with the increase of treating power, is in a limited area due to the attenuation of ultrasound.

The comparison of ultrasonic effects in different metal melts.

The effect of ultrasonic treatment of the melts is mainly ultrasonic streaming and cavitation. In this paper, the ultrasonic streaming in water, aluminum and steel melts was numerically simulated and compared. And the simulated results of streaming in water were validated by experimental results. In the experiment, the ultrasonic booster was immersed vertically into water, the ultrasonic streaming phenomenon was observed by high-speed CCD (Charge-coupled Device) system, then the streaming velocity and streamlines were obtained. The cavitation area and threshold in aluminum and steel melts were compared. The results show that the effective streaming and cavitation area in steel melt is smaller than that in aluminum melt, and far smaller than that in water. A symmetrical vortex forms both in water and aluminum melt by the drive of downward ultrasonic streaming caused by the booster tip. However, in steel melt, a double-vortex structure, including a vortex in the upper part and a vortex with reverse cycling in the lower part appears in the flow field. As a result, inclusions and air bubbles may be trapped in steel melt. The density and viscosity of the fluids are the main factors influencing ultrasonic streaming and cavitation. The results provide references for the application of ultrasonic treatment in metal melts.