SLURRY-BASED BINDER JETTING OF CERAMIC CASTING CORES

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Date

2023

Authors

Erhard, P.
Volk, W.
Guenther, D.

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Publisher

University of Texas at Austin

Abstract

The production of complex sand cores to represent internal contours in castings is typically achieved by powder-based binder jetting. However, a trade-off between the load-bearing capacity during casting and the subsequent removability from the cast part leads to design limitations. Slurry-based binder jetting allows the processing of fine powders and the economical production of sinterable ceramic cores. Its performance, potential, and challenges are presented in the context of the foundry process chain. As drying affects material properties and process efficiency, detailed investigations are carried out to control the properties via drying. Average roughness depths of 1.2 µm and flexural strengths of 25 MPa were achieved using aqueous quartz slurry and appropriate process parameters. By incorporating predetermined breaking lines into the internal geometry of hollow casting core structures, the stress generated during the solidification of the cast metal induces decoring. A promising process chain is outlined for producing efficient, close-contour coolings in high-performance castings and digital code tags for part tracking in foundries.

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