3D printing of intricate sand cores for complex copper castings

David Hughes, Luke Sutherland, Emeka Amalu

Research output: Contribution to conferenceAbstractResearchpeer-review

Abstract

Copper cast machine components are largely used in high temperature applications. Provision of internal water cooling channels in the cast, coupled with the high thermal conductivity of copper, enables cast components to perform reliably in extreme temperature ambient. However, creation of geometrically intricate internal structures in the cast is critical to improving component’s cooling efficiency and service life. Unfortunately, many of the ideal complex internal structures (cores) either cannot be manufactured using traditional methods or are not cost competitive.

This research focuses on the proof of concept. It demonstrates printing sand cores for employment in the manufacture of copper castings with complex inner cooling channels. The technique of binder jetting is used. A binder is selectively deposited onto a sand bed at room temperature to reduce dimensional distortions. The binder jetted sand is printed into cores. The cores are placed into a sand mould and filled with molten copper.

Simulation method is employed to determine the properties of the printed cores. The results are compared with that of traditional cast samples. It is found that the printed cores have consistent properties compared with the handmade cores. The surface roughness of the internal core faces is 2.03 Ra (μm). Finning is not present due to the absence of split lines found in most traditional sand cores.

The use of binder jetting technique increases manufacturability of intricate geometric cores for copper sand casting.
Original languageEnglish
Publication statusPublished - 2019
Event4th International Congress on 3D Printing (Additive Manufacturing) Technologies and Digital Industry 2019 - Porto Bello , ANTALYA, Turkey
Duration: 11 Apr 201914 Apr 2019
http://www.3dprintturkey.org/

Conference

Conference4th International Congress on 3D Printing (Additive Manufacturing) Technologies and Digital Industry 2019
Abbreviated title3D-PTC2019
CountryTurkey
CityANTALYA
Period11/04/1914/04/19
Internet address

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Foundry sand
Printing
Binders
Copper
Sand
Cooling
High temperature applications
Machine components
Cooling water
Service life
Molten materials
Thermal conductivity
Casting
Surface roughness
Castings
Temperature
Costs

Cite this

Hughes, D., Sutherland, L., & Amalu, E. (2019). 3D printing of intricate sand cores for complex copper castings. Abstract from 4th International Congress on 3D Printing (Additive Manufacturing) Technologies and Digital Industry 2019, ANTALYA, Turkey.
Hughes, David ; Sutherland, Luke ; Amalu, Emeka. / 3D printing of intricate sand cores for complex copper castings. Abstract from 4th International Congress on 3D Printing (Additive Manufacturing) Technologies and Digital Industry 2019, ANTALYA, Turkey.
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Hughes, D, Sutherland, L & Amalu, E 2019, '3D printing of intricate sand cores for complex copper castings' 4th International Congress on 3D Printing (Additive Manufacturing) Technologies and Digital Industry 2019, ANTALYA, Turkey, 11/04/19 - 14/04/19, .

3D printing of intricate sand cores for complex copper castings. / Hughes, David; Sutherland, Luke; Amalu, Emeka.

2019. Abstract from 4th International Congress on 3D Printing (Additive Manufacturing) Technologies and Digital Industry 2019, ANTALYA, Turkey.

Research output: Contribution to conferenceAbstractResearchpeer-review

TY - CONF

T1 - 3D printing of intricate sand cores for complex copper castings

AU - Hughes, David

AU - Sutherland, Luke

AU - Amalu, Emeka

PY - 2019

Y1 - 2019

N2 - Copper cast machine components are largely used in high temperature applications. Provision of internal water cooling channels in the cast, coupled with the high thermal conductivity of copper, enables cast components to perform reliably in extreme temperature ambient. However, creation of geometrically intricate internal structures in the cast is critical to improving component’s cooling efficiency and service life. Unfortunately, many of the ideal complex internal structures (cores) either cannot be manufactured using traditional methods or are not cost competitive.This research focuses on the proof of concept. It demonstrates printing sand cores for employment in the manufacture of copper castings with complex inner cooling channels. The technique of binder jetting is used. A binder is selectively deposited onto a sand bed at room temperature to reduce dimensional distortions. The binder jetted sand is printed into cores. The cores are placed into a sand mould and filled with molten copper. Simulation method is employed to determine the properties of the printed cores. The results are compared with that of traditional cast samples. It is found that the printed cores have consistent properties compared with the handmade cores. The surface roughness of the internal core faces is 2.03 Ra (μm). Finning is not present due to the absence of split lines found in most traditional sand cores. The use of binder jetting technique increases manufacturability of intricate geometric cores for copper sand casting.

AB - Copper cast machine components are largely used in high temperature applications. Provision of internal water cooling channels in the cast, coupled with the high thermal conductivity of copper, enables cast components to perform reliably in extreme temperature ambient. However, creation of geometrically intricate internal structures in the cast is critical to improving component’s cooling efficiency and service life. Unfortunately, many of the ideal complex internal structures (cores) either cannot be manufactured using traditional methods or are not cost competitive.This research focuses on the proof of concept. It demonstrates printing sand cores for employment in the manufacture of copper castings with complex inner cooling channels. The technique of binder jetting is used. A binder is selectively deposited onto a sand bed at room temperature to reduce dimensional distortions. The binder jetted sand is printed into cores. The cores are placed into a sand mould and filled with molten copper. Simulation method is employed to determine the properties of the printed cores. The results are compared with that of traditional cast samples. It is found that the printed cores have consistent properties compared with the handmade cores. The surface roughness of the internal core faces is 2.03 Ra (μm). Finning is not present due to the absence of split lines found in most traditional sand cores. The use of binder jetting technique increases manufacturability of intricate geometric cores for copper sand casting.

M3 - Abstract

ER -

Hughes D, Sutherland L, Amalu E. 3D printing of intricate sand cores for complex copper castings. 2019. Abstract from 4th International Congress on 3D Printing (Additive Manufacturing) Technologies and Digital Industry 2019, ANTALYA, Turkey.