Concise review on Pattern making process in Rapid Investment Casting: Technology, Materials & Numerical modelling aspect

Abstract

ABSTRACT The rapid investment casting (RIC) is a manufacturing process where the master patterns are produced by the means of Additive Manufacturing (AM) technologies. Fused Deposition Modelling (FDM), Stereolithography (SLA) and ink-jet rapid prototyping techniques are the common technologies utilised for wax and non-wax pattern production. RIC product quality depends on capabilities and limitations of each AM technology and materials. This paper evaluates the pros and cons of SLA, FDM, Model Maker II (MMII) and Rapid Freeze Prototyping (RFP) techniques, as well as the pattern materials used in RIC (such as wax, ice, thermoplastic, and photopolymer). A summary of the evaluation of the AM techniques shown that SLA provides the best quality patterns and FDM is the most cost effective. For materials new challenges, such as the development of iced pattern, were identified and need further investigations. Models for numerical simulations of investment casting process performed in the recent years are also reviewed in this paper. It was found that most simulation studies are used to predict the solidification time, hot spot, hot tearing areas, micro and macro-porosities.