Abstract
With the development of the powder bed 3D printing process, sand casting can be performed with methods that are more advanced than the traditional ones, thus enabling new research on applied materials. When sand is 3D-printed with cement as a binder, its casting performance is improved and sufficient thermal stability of conventional organic and inorganic binders is ensured. In this study, to ensure high resolution and strength in a physical and simple mixture of cement and sand, the compatibility for casting was confirmed using submicron-level cement with ingredients and sizes similar to commercial sand, which is uniformly controlled at 4 µm, instead of conventional sand. To enable quick 3D printing, calcium aluminate cement, which has quick binding properties, was used for high-temperature casting. The strength up to 6 h after hydration was compared to determine the curing rate of silica, mullite, and alumina sand containing cement components. By investigating the change in strength due to heat treatment and comparing the adhesion drop test results after powder bed formation, the material containing silica sand was determined as the most suitable for powder layer 3D printing for application to the mold.
Highlights
IntroductionPublisher’s Note: MDPI stays neutral with regard to jurisdictional claims in published maps and institutional affiliations
A fine powder casting usable for powder bed 3D printing, in which calcium aluminate cement (CAC) was mixed, was manufactured by varying the sand used for sand casting
Droplet absorption time and flowability were optimized at 20% cement volume ratio of CAC cement for each sand
Summary
Publisher’s Note: MDPI stays neutral with regard to jurisdictional claims in published maps and institutional affiliations. The advancements in the casting technology though the 3D printing process satisfies the price competitiveness and improvement in product performance in the sand casting market, thereby rapidly competing with the classic casting method [1]. Functional inorganic materials that can be used at high temperatures, such as castables, using existing cement binders, require high-temperature thermal stability for casting. Mixing cement and foundry sand prevents toxic emissions from conventional 3D printing operations, wherein organic and inorganic binders are mainly used, and simplifies the post-processes [2,3]
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