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- Title
Water-Soluble Sand Core Made by Binder Jetting Printing with the Binder of Potassium Carbonate Solution.
- Authors
Zhang, Long; Yang, Xiaona; Ran, Songlin; Zhang, Lina; Hu, Chunyang; Wang, Hao
- Abstract
Water-soluble cores are an effective solution for complex inner cavity castings due to its excellent ability of leaching out in water. Compared with the rapid development of 3D printing sand mold/core, the water-soluble core additive manufacturing technology is limited by its material properties because water-soluble inorganic salt materials tend to agglomerate and are transparent for the visible and near-infrared lasers. In this study, a process based on direct jetting potassium carbonate solution onto powder bed mix with ceramic sand and bentonite followed with post-treatment was proposed to prepare the water-soluble sand core. The mechanical property of the core was detected in different stages of the forming process, and the mechanism of strength and collapse was analyzed with the aid of phase diagram and scanning electron microscopy. The results show that the strength of binder jetting core exceeds 2 MPa after sintering at 900 °C for 10 min via pre-sintering and soaking, and the residual strength of the core decreases to 0.12 MPa, which guarantees the leachability of the core out of a casting under a slight vibration. Liquid bridge between sand grains built up in the process of binder jetting transforms into K2CO3 bonding bridge during the heating process, and a reticular structure of KAlSimOn grows up with the increase of sintering temperature and the extension of time, which explains the pre-sintered core maintains the original shape in K2CO3 solution and the sintered core has a low strength after soaking in water. What is more, a casting trial of tee pipe was conducted to verify the suitability of the developed cores for aluminum alloy castings with complex internal cavities.
- Subjects
POTASSIUM carbonate; ALUMINUM castings; FOUNDRY sand; COREMAKING; SCANNING electron microscopy
- Publication
International Journal of Metalcasting, 2023, Vol 17, Issue 3, p2286
- ISSN
1939-5981
- Publication type
Article
- DOI
10.1007/s40962-022-00940-4