Experimental and numerical characterization of functional properties of sand molds produced by additive manufacturing (3D printing by jet binding) in a fast foundr

Abstract : Nowadays, traditionally manufactured sand molds and cores for metal casting are being progressively replaced by additively processed sand molds in aerospace/automotive industry, facilitating the production of quality cast parts with complex shapes. The type of additive manufacturing technology used to manufacture 3DP parts in foundries is known as powder-binder-jetting process. In this technology, the molds are produced without the use of any kind of additive tools and in a completely automated way using the layer based construction method. One of the most popular binder systems used in the manufacturing of 3DP mold is a furan-based resin binder, which holds the grain particles together. Their amounts and ratios can influence significantly the 3D printed mold properties, affecting casting quality. Therefore, it is essential to characterize the effects process parameters on the functionality of the 3DP molds. In the present work, the mechanical behavior of 3DP sand molds with varying printing process parameters was first investigated, followed by mass transport properties. To do so, a series of three-point bending strength tests, density measurements, porosity measurements and permeability tests were performed on the 3DP molds. Furthermore, the influence of time, temperature and binder volume fraction on the mechanical and mass transport properties was also investigated. Advanced modelling of the pore space was performed by using the reconstructed images provided by X-ray computed tomography, following different steps: X-ray CT scanning of small 3DP mold specimen, 3D volumetric reconstruction of data, numerical simulations for the prediction of permeability from the reconstructed volume, and pore network modelling for the determination of the pore size distribution. Experiments were also designed to investigate the 3D printed molds in terms of mold erosion during metal casting, in order to select the molding parameters to print 3D printed parts not only with good mechanical and mass transport properties but also to minimize the mold erosion during metal casting. Furthermore, a reverse engineering method for determination of the erosion resistance of sand molds has been established, to study the volume of the eroded surface.
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Saptarshee Mitra. Experimental and numerical characterization of functional properties of sand molds produced by additive manufacturing (3D printing by jet binding) in a fast foundr. Other [cond-mat.other]. Ecole nationale supérieure d'arts et métiers - ENSAM, 2019. English. ⟨NNT : 2019ENAM0043⟩. ⟨tel-02466819v1⟩

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