Expendable Pattern Research Articles

Effect of Melt Velocity on Density of Aluminum Alloy Castings in Expendable Pattern Casting Process

Effect of Melt Velocity on Density of Aluminum Alloy Castings in Expendable Pattern Casting Process

Effect of Sand Material Type on Heat Absorbing Properties of Mold in Expendable Pattern Casting Process of Aluminum Alloy Castings

Effect of Sand Material Type on Heat Absorbing Properties of Mold in Expendable Pattern Casting Process of Aluminum Alloy Castings

Effects of Sand Material Type and Vibration Conditions on Appearance Quality of Aluminum Alloy Castings in Expendable Pattern Casting Process

Effects of Sand Material Type and Vibration Conditions on Appearance Quality of Aluminum Alloy Castings in Expendable Pattern Casting Process

Effects of Reduced Pressure and Casting Design on Mold Filling in Expendable Pattern Casting Process of Thin Wall Aluminum Alloy Castings

Effects of Reduced Pressure and Casting Design on Mold Filling in Expendable Pattern Casting Process of Thin Wall Aluminum Alloy Castings

Effects of Reduced Pressure and Casting Design on Mold Filling in Expendable Pattern Casting Process of Thin Wall Aluminum Alloy Castings

Effects of Reduced Pressure and Casting Design on Mold Filling in Expendable Pattern Casting Process of Thin Wall Aluminum Alloy Castings

Microstructure and mechanical properties of AZ91D magnesium alloy by expendable pattern shell casting with different mechanical vibration amplitudes and pouring temperatures

To refine the microstructure and improve the mechanical properties of AZ91D alloy by expendable pattern shell casting (EPSC), the mechanical vibration method was applied in the solidification process of the alloy. The effects of amplitude and pouring temperature on microstructure and mechanical properties of AZ91D magnesium alloy were studied. The results indicated that the mechanical vibration remarkably improved the sizes, morphologies and distributions of the primary α-Mg phase and β-Mg17Al12 phase, and the densification and tensile properties of the AZ91D alloy. With an increase in amplitude, the microstructures were gradually refined, resulting in a continuous increase in mechanical properties of the AZ91D alloy. While, with the increase of pouring temperature, the microstructures were continuously coarsened, leading to an obvious decrease of the mechanical properties. The tensile strength and yield strength of the AZ91D alloy with a vibration amplitude of 1.0 mm and a pouring temperature of 730 °C were 60% and 38% higher than those of the alloy without vibration, respectively.

Effect of Melt Velocity on Density of Aluminum Alloy Castings in Expendable Pattern Casting Process

Effect of Melt Velocity on Density of Aluminum Alloy Castings in Expendable Pattern Casting Process

Effects of Reduced Pressure, Casting Design and Heat Transfer Resistance of Liquid Resin on Mold Filling in Expendable Pattern Casting Process of Aluminum Alloy

Effects of Reduced Pressure, Casting Design and Heat Transfer Resistance of Liquid Resin on Mold Filling in Expendable Pattern Casting Process of Aluminum Alloy

Effect of Vibration Fluidity of Packing Sand on Casting Appearance in Expendable Pattern Casting Process

Effect of Vibration Fluidity of Packing Sand on Casting Appearance in Expendable Pattern Casting Process

Effects of Reduced Pressure, Casting Design and Heat Transfer Resistance of Liquid Resin on Mold Filling in Expendable Pattern Casting Process of Aluminum Alloy

Effects of Reduced Pressure, Casting Design and Heat Transfer Resistance of Liquid Resin on Mold Filling in Expendable Pattern Casting Process of Aluminum Alloy

Effect of Vibration Condition of Flask on Dimensional Accuracy of Casting in Expendable Pattern Casting Process

Effect of Vibration Condition of Flask on Dimensional Accuracy of Casting in Expendable Pattern Casting Process

Effect of Sand Materials on Appearance and Dimensional Accuracy of Casting in Expendable Pattern Casting Process

Effect of Sand Materials on Appearance and Dimensional Accuracy of Casting in Expendable Pattern Casting Process

TiC-Fe-Based Composite Coating Prepared by Self-Propagating High-Temperature Synthesis

TiC-Fe-based composite coatings were prepared in situ by self-propagating high-temperature synthesis combined with vacuum expendable pattern casting process. The band-like TiC phase embedded in a continuous Fe binder. There were no obvious defects and impurities at the interface between coatings and matrices. Fe presented consecutively in the coating zones and substrate zones without interruption and the microhardness in the cross-sectional area of the coating–matrix reduces continuously from the coating to the matrix area, indicating a good metallurgical bonding between the coatings and matrices. The effect of casting temperature on the microstructure and hardness of TiC-Fe-based composite coating was investigated in detail. The TiC particles formed at low casting temperature were nearly spherical in shape, and the size of TiC particles increased with increasing casting temperature due to more agglomeration. The hardness of the coatings increased first and then decreased with increasing casting temperature, and reached the highest value of 68 HRC when the casting temperature was 1773 K (1500 °C), which was twice more than that of the matrix.

Cooling Capacity of Mold and Effect of Pattern Deformation on Sand Fluidity in Expendable Pattern Casting Process using Artificial Sand

Cooling Capacity of Mold and Effect of Pattern Deformation on Sand Fluidity in Expendable Pattern Casting Process using Artificial Sand

Effect of Coat Permeability on Mold Filling in Expendable Pattern Casting Process of Thin Wall Aluminum Alloy Casting

Effect of Coat Permeability on Mold Filling in Expendable Pattern Casting Process of Thin Wall Aluminum Alloy Casting

Effect of Thermal Insulation Coat on Mold Filling for Thin Wall Aluminum Alloy Casting in Expendable Pattern Casting Process

Effect of Thermal Insulation Coat on Mold Filling for Thin Wall Aluminum Alloy Casting in Expendable Pattern Casting Process

Direct rapid prototyping evaluation on multijet and fused deposition modeling patterns for investment casting

The continuation from rapid prototyping into rapid tooling technologies allows speedy fabrication of sacrificial patterns for investment casting process. Direct expendable pattern fabrication with intricate features using rapid prototyping techniques significantly reduces the fabrication cost when associated with single- or low-volume production. During investment casting process, rapid prototyping patterns are subjected to high melting temperatures, high viscosities, and high thermal stress such as dewaxing and shell mold cracking. Furthermore, ceramic shell may cause crack during melting and burning out of the patterns and also incomplete collapsibility. Although rapid prototyping process can build parts with high stiffness rapidly, the part surface suffered a staircase effect and shrinkage during investment casting process solidification. This paper presents a direct approach of multijet modeling and fused deposition modeling on acrylate- and acrylonitrile–butadiene–styrene-based materials to be used as expendable patterns for the investment casting process. Thermal analyses were conducted on the rapid prototyping materials that exhibit mass loss and expansion. Quality assessment and benchmarking were performed between the rapid prototyping and the metal part on accuracy, surface roughness, and part built time. It was found that both the materials have dimensional deviation when employed in investment casting process and acrylate patterns have better surface roughness as compared to acrylonitrile–butadiene–styrene patterns. Additionally, multijet modeling recorded a significantly shorter lead time when more than a single part can be produced during the rapid prototyping process. It was observed that the shell mold after burnout experiences cracking. Results also showed that acrylate-based materials decomposed above 500℃, meanwhile acrylonitrile–butadiene–styrene was above 600℃. Acrylate material had a coefficient of thermal expansion and linear dimensional deviation as compared with acrylonitrile–butadiene–styrene. No ash was observed in the ceramic molds when the part burnout temperatures are above 500℃ acrylate material and 600℃ for acrylonitrile–butadiene–styrene.

薄肉アルミニウム合金の消失模型鋳造法における溶湯流動長

薄肉アルミニウム合金の消失模型鋳造法における溶湯流動長

Effect of Coat Permeability on Melt Velocity of Molten Aluminum Alloy in Expendable Pattern Casting Process

Effect of Coat Permeability on Melt Velocity of Molten Aluminum Alloy in Expendable Pattern Casting Process

Effect of Coat Permeability on Mold Filling in Expendable Pattern Casting Process of Thin Wall Aluminum Alloy Casting

Effect of Coat Permeability on Mold Filling in Expendable Pattern Casting Process of Thin Wall Aluminum Alloy Casting