Characterisation of 3D printed sand moulds using micro-focus X-ray computed tomography
TypeArticles dans des revues avec comité de lecture
Purpose – Micro-focus X-ray computed tomography (CT) can be used to quantitatively evaluate the packing density, pore connectivity andvprovide the basis for specimen derived simulations of gas permeability of sand mould. This non-destructive experiment or following simulations can be done on any section of any size sand mould just before casting to validate the required properties. This paper aims to describe the challenges of this method and use it to simulate the gas permeability of 3D printed sand moulds for a range of controlling parameters. The permeability simulations are compared against experimental results using traditional measurement techniques. It suggests that a minimum volume of only 700 700 700 mm3 is required to obtain, a reliable and most representative than the value obtained by the traditional measurement technique, the simulated permeability of a specimen. Design/methodology/approach – X-ray tomography images were used to reconstruct 3D models to simulate them for gas permeability of the 3D printed sand mould specimens, and the results were compared with the experimental result of the same. Findings – The influence of printing parameters, especially the re-coater speed, on the pore connectivity of the 3D printed sand mould and related permeability has been identified. Characterisation of these sand moulds using X-ray CT and its suitability, compared to the traditional means, are also studied. While density and 3PB strength are a measure of the quality of the moulds, the pore connectivity from the tomographic images precisely relates to the permeability. The main conclusions of the present study are provided below. A minimum required sample size of 700 700 700 mm3 is required to provide representative permeability results. This was obtained from sand specimens with an average sand grain size of 140 mm, using the tomographic volume images to define a 3D mesh to run permeability calculations. Z-direction permeability is always lower than that in the X-/Ydirections due to the lower values of X-(120/140 mm) and Y-(101.6 mm) resolutions of the furan droplets. The anisotropic permeability of the 3D printed sand mould is mainly due to, the only adjustable, X-directional resolution of the furan droplets; the Y-directional resolution is a fixed distance, 102.6 mm, between the printhead nozzles and the Z-directional one is usually, 280 mm, twice the size of an average sand grain.A non-destructive and most representative permeability value can be obtained, using the computer simulation, on the reconstructed 3D X-ray tomography images obtained on a specific location of a 3D printed sand mould. This saves time and effort on printing a separate specimen for the traditional test which may not be the most representative to the printed mould. Originality/value – The experimental result is compared with the computer simulated results.
Showing items related by title, author, creator and subject.
UPADHYAY, Meet; SIVARUPAN, Tharmalingam; EL MANSORI, Mohamed (Elsevier BV, 2017)There are many 3D printing technologies available, and each technology has its strength and weakness. The 3D printing of sand moulds, by binder jetting technology for rapid casting, plays a vital role in providing a better ...
SIVARUPAN, Tharmalingam; EL MANSORI, Mohamed; CONIGLIO, Nicolas; DARGUSCH, Matthew (Elsevier BV, 2020)3D printed sand molds for the casting industry play a vital role in manufacturing intricate parts from a computer model. The possibility of producing fairly significant structural castings using a small job-box 3D sand ...
CONIGLIO, Nicolas; SIVARUPAN, T.; EL MANSORI, Mohamed (SPRINGER, 2018)The development of sand mold three-dimensional printing technologies enables the manufacturing of molds without the use of a physical model. However, the effects of the three-dimensional printing process parameters on the ...
Controllable mesostructure, magnetic properties of soft magnetic Fe-Ni-Si by using selective laser melting from nickel coated high silicon steel powder KANG, Nan; EL MANSORI, Mohamed; GUITTONNEAU, Fabrice; LIAO, Hanlin; FU, Y.; AUBRY, E. (Elsevier BV, 2018)Fe-Ni-Si soft magnetic parts, using Ni coated high silicon steel powder, were manufactured by selective laser melting process. The type of defect changes from porosity to cracks and the relative density increases, from 50% ...
In-situ synthesis of aluminum/nano-quasicrystalline Al-Fe-Cr composite by using selective laser melting KANG, Nan; EL MANSORI, Mohamed; LIN, X.; GUITTONNEAU, Fabrice; LIAO, H.L.; HUANG, W.D.; CODDET, C. (Elsevier BV, 2018)In this research, Al-Fe-Cr quasicrystal (QC) reinforced Al-based metal matrix composites were in-situ manufactured by using selective laser melting (SLM) from the powder mixture. The parametrical optimization based on our ...