International journal of metalcasting, Mar 2, 2024
Renewed interest in inorganic binders for sand molding has also intensified research on different... more Renewed interest in inorganic binders for sand molding has also intensified research on different forms of it. In this study, solid inorganic sodium silicate binder was tested with different additives to see how these affected the silica mold quality. The five additives used were: glucose, sucrose, boric acid, aluminum oxide and iron(III)oxide powders. The mold quality was assessed through tests like bending strength, tensile strength, hot distortion, wear resistance, gas evolution and collapsibility tests. In addition, SEM imaging was done on some select mold fracture samples. In the end, a casting trial was carried out followed by a surface roughness and defects analysis. A reduction in mold strength was noticed with glucose and boric acid, while collapsibility was improved by glucose, sucrose and boric acid additives. Casting trials have shown the best surface finish to be obtained with sucrose additive. All the casts in general showed some penetration; however, repeat casts have proven that altering some casting parameters could result in casts with excellent surface finish using solid silicates.
International Journal of Metalcasting, Mar 12, 2023
Efficient manufacturing of tooling and patterns is an essential part of a good foundry process. T... more Efficient manufacturing of tooling and patterns is an essential part of a good foundry process. Traditional patternmaking methods have been honed to almost perfection during the years. Additive manufacturing has been growing as an industry and presents many new possibilities for the foundry industry. However, many additive manufacturing technologies do not currently provide usable sizes and scales for foundries to properly use. Fused granular fabrication (FGF) in conjunction with finish machining might provide an answer to this issue, with printing volumes and speeds many times of those compared to filament-based fused deposition modeling printing. In this work, some traditional patternmaking materials are compared to a FGF manufactured one based on polylactic acid and cellulose blend, and their characteristics are discussed. 3D scanning of as-printed geometry shows variations inherent to material extrusion methods, while the final machined state shows comparable results to traditional polyurethane model material. The combination of high-volume material extrusion with machining to final dimensions might allow more utilization of additive manufacturing in patternmaking, especially when combined with high-performance polymer materials.
International journal of metalcasting, Mar 2, 2024
Renewed interest in inorganic binders for sand molding has also intensified research on different... more Renewed interest in inorganic binders for sand molding has also intensified research on different forms of it. In this study, solid inorganic sodium silicate binder was tested with different additives to see how these affected the silica mold quality. The five additives used were: glucose, sucrose, boric acid, aluminum oxide and iron(III)oxide powders. The mold quality was assessed through tests like bending strength, tensile strength, hot distortion, wear resistance, gas evolution and collapsibility tests. In addition, SEM imaging was done on some select mold fracture samples. In the end, a casting trial was carried out followed by a surface roughness and defects analysis. A reduction in mold strength was noticed with glucose and boric acid, while collapsibility was improved by glucose, sucrose and boric acid additives. Casting trials have shown the best surface finish to be obtained with sucrose additive. All the casts in general showed some penetration; however, repeat casts have proven that altering some casting parameters could result in casts with excellent surface finish using solid silicates.
International Journal of Metalcasting, Mar 12, 2023
Efficient manufacturing of tooling and patterns is an essential part of a good foundry process. T... more Efficient manufacturing of tooling and patterns is an essential part of a good foundry process. Traditional patternmaking methods have been honed to almost perfection during the years. Additive manufacturing has been growing as an industry and presents many new possibilities for the foundry industry. However, many additive manufacturing technologies do not currently provide usable sizes and scales for foundries to properly use. Fused granular fabrication (FGF) in conjunction with finish machining might provide an answer to this issue, with printing volumes and speeds many times of those compared to filament-based fused deposition modeling printing. In this work, some traditional patternmaking materials are compared to a FGF manufactured one based on polylactic acid and cellulose blend, and their characteristics are discussed. 3D scanning of as-printed geometry shows variations inherent to material extrusion methods, while the final machined state shows comparable results to traditional polyurethane model material. The combination of high-volume material extrusion with machining to final dimensions might allow more utilization of additive manufacturing in patternmaking, especially when combined with high-performance polymer materials.
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Papers by Juhani Orkas