Abstract
The use of rapid prototyping technologies for the production of sacrificial sand moulds for the foundry industry has been previously researched, but with selective laser sintering as the main technology, and with different methods of processing and materials as critical variables. With the proliferation of 3D printers and the relatively easy and economical production of moulds with special sands supplied by Z-Corporation, it is time that direct metal casting through 3D printing is scientifically investigated. Knowledge of the influence of various process parameters on the quality of moulds and subsequent castings is essential in effectively employing direct metal casting in real-world applications. This paper presents results of experimental investigations carried out to establish the influences of critical factors, such as curing times and temperatures, on mechanical characteristics, such as strength and permeability, of sand moulds produced by 3D printing. The dimensional and surface qualities of castings produced using the casting grade aluminium, A356, and the effectiveness of various mould surface coatings, and causes of casting defects, are also investigated. Statistically-designed experiments are employed for the systematic analysis of the individual roles of direct metal casting parameters, as well as their combined effects.
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