Figure 1.
(a) 3D model of EGR (exhaust gas recirculation) joint with gate, (b) 3D model of EGR joint module.
Figure 2.
EGR joint module and its shell model.
Figure 3.
Simulation results of filling process of EGR joint.
Figure 4.
Simulation results of solidification process of the EGR joint.
Figure 5.
Simulation results of shrinkage cavity position of the EGR joint.
Figure 6.
SLA printing EGR joint sample of photosensitive resin.
Figure 7.
Module of the EGR joint.
Figure 8.
(a) Two layered and (b) four layered shells of the EGR joint.
Figure 9.
Cracked mold shell seen from different angles (a) and (b)
Figure 10.
Four printed parts. (a) EGR connector printout; (b) pad prints; (c) nail in the plate print; (d) sewing machine accessory prints.
Figure 11.
Castings of four parts. (a) EGR joint casting; (b) casting of pad blocks; (c) nail in the plate casting; (d) sewing machine parts casting.
Figure 12.
(a) The EnvisionTEC Ultra 3SP machine and (b) a grain selector made from E-glass.
Figure 13.
The MakerBot Replicator 2X experimental 3D printer.
Figure 14.
(a) White ABS material. (b) Grain selectors made of ABS.
Figure 15.
(a) MakerBot Replicator 2X experimental 3D printer and (b) a grain selector made of EC500.
Figure 16.
(a) CoLiDo DLP 2.0 3D printer and (b) a grain selector made of photosensitive resin.
Figure 17.
Grain selectors manufactured by different 3D printing methods.
Figure 18.
(a) The assembled wax pattern with the spiral grain selector, and (b) the final green ceramic shell after stuccoing.
Figure 19.
ALD vacuum Bridgman furnace installed at the Foundry Institute.
Figure 20.
(a) Bridgman process during pouring superalloy; (b) Bridgman process during withdrawing.
Figure 21.
Casting mold in the Bridgman furnace after casting.
Figure 22.
Grain selectors cast from MM247LC.
Figure 23.
Remaining grain selectors manufactured with 3D printing material after the dewaxing process.
Figure 24.
Failed ceramic shell mold for EC500 material.
Figure 25.
Measured parameters of 3D printed pattern and cast grain selectors.
Figure 26.
Dimensional measurement schematic.
Figure 27.
Dimensional measurement schematic (roughness range from 3.72 μm to 6.71 μm).
Figure 28.
Dimensional measurement schematic.
Table 1.
Properties of resin 8000, ABS plastic and PLA plastic.
Index | Resin8000 | ABS | PLA |
---|
Print accuracy/mm | 0.02 | 0.1 | 0.1 |
Glass transition temperature/°C | 70 | 105 | 60 |
Melting temperature/°C | 165–195 | 150–180 | 165–185 |
Fluidity | bad | normal | normal |
Shrinkage rate | small | 5% | small |
Weldability | bad | normal | normal |
Coating performance | good | normal | Normal |
Table 2.
Mechanical properties of E-glass.
Parameters | Value at 30 s × 2 Post Curing Time | Value at 5 min × 2 Post Curing Time |
---|
Tensile Strength | 48 MPa | 21 MPa |
Tensile Modulus | 1950 MPa | 2000 MPa |
Elongation at Break | 3% | 1.15% |
Flexural Strength | 79 MPa | 75 MPa |
Table 3.
Mechanical properties of EC500.
Tensile Strength | 57 MPa |
Elongation at Break | 3.6% |
Flexural Strength | 129 MPa |
Flexural Modulus | 3155 MPa |
Heat deflection temperature | 130 °C at 0.455 MPa, 78 °C at 1.82 MPa |
Specific gravity | 1.10–1.11g\cm3 |
Viscosity | 760cp at 25 °C |
Table 4.
Composition of the front slurry.
Contents | Trademark | Percentage of Mass | 25 Kg Mixture |
---|
Distilled water | - | 5.50% | 1.37 kg |
Binder | Ludox Px-30 | 17.82% | 4.45 kg |
Benetzer | victawet 12 | 0.30% | 0.075 kg |
Defoamer | Brust100 | 0.03% | 0.007 kg |
Condenser | DolapixCE64 | 0.25% | 0.062 kg |
Condenser | DolapixA88 | 0.10% | 0.025 kg |
Solid fuel | Matroxid MR70 | 20% | 5 kg |
Solid fuel | Nabalox NO113 | 6% | 1.5 kg |
Solid fuel | Alodur WSK30-70um | 50% | 12.5 kg |
Table 5.
Composition of the back slurry.
Contents | Trademark | Percentage of Mass | 20 kg Mixture | 25 kg Mixture |
---|
Binder | Ludox Px-30 | 24.73% | 4.94 kg | 6.18 kg |
Benetzer | victawet 12 | 0.25% | 0.05 kg | 0.062 kg |
Defoamer | Brust100 | 0.02% | 0.004 kg | 0.005 kg |
Solid fuel | Matroxid MR70 | 45% | 9.0 kg | 11.25 kg |
Solid fuel | Alodur WSK30-70um | 30% | 6.0 kg | 7.5 kg |
Table 6.
Chemical composition of MM247LC (wt %).
C | Cr | Co | Mo | W | Ta | Ti | Al | B | Zr | Hf | Ni |
---|
0.07 | 8 | 9 | 0.5 | 10 | 3.2 | 0.7 | 5.6 | 0.015 | 0.01 | 1.4 | Bal |
Table 7.
Overview of the cast grain selector and the corresponding 3D printed pattern.
Number | Shape of Grain Selector | Pattern Material | Casting Material |
---|
1 | 2D-C-column base | ABS | MM247LC |
2 | 2D-C-square base | ABS | MM247LC |
3 | 3D-column base | ABS | MM247LC |
4 | 3D-column base | Photosensitive Resin | MM247LC |
5 | 2D-Z-square base | ABS | MM247LC |
6 | 2D-Z-column base | E glass | MM247LC |
7 | 2D-Z-column base | ABS | MM247LC |
8 | 3D-column base | EC500 | failed |
Table 8.
Dimensional tolerances for castings (lS0 8062-1984).
Basic Size of Casting | Grade of Tolerance |
---|
from | to | CT3 | CT4 | CT5 | CT6 | CT7 |
| 3 | 0.14 | 0.20 | 0.28 | 0.40 | 0.56 |
3 | 6 | 0.16 | 0.24 | 0.32 | 0.48 | 0.64 |
6 | 10 | 0.18 | 0.26 | 0.36 | 0.52 | 0.74 |
10 | 16 | 0.20 | 0.28 | 0.38 | 0.54 | 0.78 |
16 | 25 | 0.22 | 0.30 | 0.42 | 0.58 | 0.82 |
25 | 40 | 0.24 | 0.32 | 0.46 | 0.64 | 0.90 |
Table 9.
EGR joint casting size measurement results.
No. | Standard Value/mm | Measured Value/mm | Error/mm | Grade of Tolerance |
---|
1 | 20.10 | 19.96 | −0.14 | CT6 |
2 | 27.50 | 27.55 | +0.05 | CT6 |
3 | φ13.60 | φ13.36 | −0.24 | CT6 |
4 | φ23.80 | φ23.34 | −0.46 | CT6 |
Table 10.
Dimension measurements of the block castings.
No. | Standard Value/mm | Measured Value/mm | Error/mm | Grade of Tolerance |
---|
1 | 7.00 | 7.11 | +0.11 | CT6 |
2 | φ8.20 | φ8.13 | −0.07 | CT6 |
3 | R14.75 | R14.89 | +0.24 | CT6 |
4 | 23.00 | 22.88 | −0.12 | CT6 |
Table 11.
Nail in the plate casting size measurement results.
No. | Standard Value/mm | Measured Value/mm | Error/mm | Grade of Tolerance |
---|
1 | 95.40 | 95.09 | −0.31 | CT6 |
2 | 25.50 | 25.24 | −0.26 | CT6 |
3 | 32.85 | 32.96 | +0.11 | CT6 |
| φ6.05 | φ6.09 | +0.04 | CT6 |
Table 12.
Sewing machine accessories’ casting size measurement results.
No. | Standard Value/mm | Measured Value/mm | Error/mm | Grade of Tolerance |
---|
1 | 5.50 | 5.58 | +0.08 | CT6 |
2 | 14.10 | 14.27 | +0.17 | CT6 |
3 | 10.10 | 9.94 | −0.06 | CT6 |
4 | φ8.50 | φ8.36 | −0.14 | CT6 |
Table 13.
EGR joint casting surface roughness measurement results.
No. | 1 | 2 | 3 | 4 | 5 |
---|
Measured value/µm | 4.98 | 5.12 | 5.00 | 5.16 | 4.71 |
No. | 6 | 7 | 8 | 9 | 10 |
Measured value/µm | 5.26 | 5.08 | 5.43 | 5.14 | 5.09 |
Table 14.
Test results of surface roughness of spacer castings.
No. | 1 | 2 | 3 | 4 | 5 |
---|
Measured value/µm | 4.88 | 4.63 | 5.16 | 4.61 | 4.39 |
No. | 6 | 7 | 8 | 9 | 10 |
Measured value/µm | 4.55 | 4.39 | 5.23 | 3.72 | 4.98 |
Table 15.
Nail in the plate surface roughness measurement results.
No. | 1 | 2 | 3 | 4 | 5 |
---|
Measured value/µm | 4.29 | 4.81 | 5.56 | 5.53 | 6.71 |
No. | 6 | 7 | 8 | 9 | 10 |
Measured value/µm | 5.39 | 6.25 | 5.48 | 5.99 | 4.62 |
Table 16.
Sewing machine parts’ surface roughness measurement results.
No. | 1 | 2 | 3 | 4 | 5 |
---|
Measured value/µm | 4.03 | 5.11 | 4.88 | 4.95 | 4.92 |
No. | 6 | 7 | 8 | 9 | 10 |
Measured value/µm | 5.32 | 6.06 | 5.25 | 4.62 | 4.03 |
Table 17.
Dimensional measurements of number 1 (Nr.1) 3D printed pattern (ABS).
Pattern | Parameter | Measured Value | Standard Value | Error with Signs | Dimensional Accuracy |
---|
Nr.1 | Spiral | 3.17 | 3 | 0.17 | CT4 |
| Height | 30.29 | 30 | 0.29 | CT4 |
| Diameter-L | 15.01 | 15 | 0.01 | CT3 |
| Diameter-M | 14.97 | 15 | −0.03 | CT3 |
| Diameter-H | 15 | 15 | 0 | CT3 |
Table 18.
Dimensional measurements of Nr.2 3D printed pattern (ABS).
Pattern | Parameter | Measured Value | Standard Value | Error with Signs | Dimensional Accuracy |
---|
Nr.2 | Spiral | 3.15 | 3 | 0.15 | CT 4 |
| Height | 30.22 | 30 | 0.22 | CT 3 |
| Length-L | 13.03 | 13 | 0.03 | CT 3 |
| Length-M | 13.03 | 13 | 0.03 | CT 3 |
| Length-H | 13.04 | 13 | 0.04 | CT 3 |
Table 19.
Dimensional measurements of Nr.3 3D printed pattern (ABS).
Pattern | Parameter | Measured Value | Standard Value | Error with Signs | Dimensional Accuracy |
---|
Nr.3 | Spiral | 3.31 | 3 | 0.31 | CT 6 |
| Height | 30.27 | 30 | 0.27 | CT 4 |
| Diameter-L | 15.02 | 15 | 0.02 | CT 3 |
| Diameter-M | 14.96 | 15 | −0.04 | CT 3 |
| Diameter-H | 15 | 15 | 0 | CT 3 |
Table 20.
Dimensional measurements of Nr.4 3D printed pattern (photosensitive resin).
Pattern | Parameter | Measured Value | Standard Value | Error with Signs | Dimensional Accuracy |
---|
Nr.4 | Spiral | 3.35 | 3 | 0.35 | CT 6 |
| Height | 30.35 | 30 | 0.35 | CT 5 |
| Diameter-L | 15.09 | 15 | 0.09 | CT 3 |
| Diameter-M | 15.1 | 15 | 0.1 | CT 3 |
| Diameter-H | 15.03 | 15 | 0.03 | CT 3 |
Table 21.
Dimensional measurements of Nr.5 3D printed pattern (ABS).
Pattern | Parameter | Measured Value | Standard Value | Error with Signs | Dimensional Accuracy |
---|
Nr.5 | Spiral | 3.07 | 3 | 0.07 | CT 3 |
| Height | 30.14 | 30 | 0.14 | CT 3 |
| Length-L | 12.95 | 13 | −0.05 | CT 3 |
| Length-M | 12.94 | 13 | −0.06 | CT 3 |
| Length-H | 12.95 | 13 | −0.05 | CT 3 |
Table 22.
Dimensional measurements of Nr.6 3D printed pattern (E-glass).
Pattern | Parameter | Measured Value | Standard Value | Error with Signs | Dimensional Accuracy |
---|
Nr.6 | Spiral | 3.05 | 3 | 0.05 | CT 3 |
| Height | 29.78 | 30 | −0.22 | CT 3 |
| Diameter-L | 14.61 | 15 | −0.39 | CT 6 |
| Diameter-M | 14.74 | 15 | −0.26 | CT 4 |
| Diameter-H | 14.85 | 15 | −0.15 | CT 3 |
Table 23.
Dimensional measurements of Nr.7 3D printed pattern (ABS).
Pattern | Parameter | Measured Value | Standard Value | Error with Signs | Dimensional Accuracy |
---|
Nr.7 | Spiral | 3.12 | 3 | 0.12 | CT 3 |
| Height | 30.16 | 30 | 0.16 | CT 3 |
| Diameter-L | 14.99 | 15 | −0.01 | CT 3 |
| Diameter-M | 14.96 | 15 | −0.04 | CT 3 |
| Diameter-H | 15.02 | 15 | 0.02 | CT 3 |
Table 24.
Dimensional measurements of Nr.1 cast grain selector.
Casting | Parameter | Measured Value | Standard Value | Error with Signs | Dimensional Accuracy |
---|
Nr.1 | Spiral | 3.24 | 3 | 0.24 | CT 5 |
| Height | 30.54 | 30 | 0.54 | CT 6 |
| Diameter-L | 14.85 | 15 | −0.15 | CT 3 |
| Diameter-M | 14.62 | 15 | −0.38 | CT 5 |
| Diameter-H | 14.63 | 15 | −0.37 | CT 5 |
Table 25.
Dimensional measurements of Nr.2 cast grain selector.
Casting | Parameter | Measured Value | Standard Value | Error with Signs | Dimensional Accuracy |
---|
Nr.2 | Spiral | 3.15 | 3 | 0.15 | CT 4 |
| Height | 30.26 | 30 | 0.26 | CT 4 |
| Length-L | 12.83 | 13 | −0.17 | CT 3 |
| Length-M | 12.8 | 13 | −0.2 | CT 3 |
| Length-H | 12.78 | 13 | −0.22 | CT 4 |
Table 26.
Dimensional measurements of Nr.3 cast grain selector.
Casting | Parameter | Measured Value | Standard Value | Error with Signs | Dimensional Accuracy |
---|
Nr.3 | Spiral | 3.28 | 3 | 0.28 | CT 5 |
| Height | 30.27 | 30 | 0.27 | CT 4 |
| Diameter-L | 14.92 | 15 | −0.08 | CT 3 |
| Diameter-M | 14.76 | 15 | −0.24 | CT 4 |
| Diameter-H | 14.8 | 15 | −0.2 | CT 3 |
Table 27.
Dimensional measurements of Nr.4 cast grain selector.
Casting | Parameter | Measured Value | Standard Value | Error with Signs | Dimensional Accuracy |
---|
Nr.4 | Spiral | 3.5 | 3 | 0.5 | CT 7 |
| Height | 30.81 | 30 | 0.81 | CT 7 |
| Diameter-L | 14.9 | 15 | −0.1 | CT 3 |
| Diameter-M | 14.83 | 15 | −0.17 | CT 3 |
| Diameter-H | 14.96 | 15 | −0.04 | CT 3 |
Table 28.
Dimensional measurements of Nr.5 cast grain selector.
Casting | Parameter | Measured Value | Standard Value | Error with Signs | Dimensional Accuracy |
---|
Nr.5 | Spiral | 3.17 | 3 | 0.17 | CT 4 |
| Height | 30.41 | 30 | 0.41 | CT 5 |
| Length-L | 12.95 | 13 | −0.05 | CT 3 |
| Length-M | 12.79 | 13 | −0.21 | CT 4 |
| Length-H | 12.94 | 13 | −0.06 | CT 3 |
Table 29.
Dimensional measurements of Nr.6 cast grain selector.
Casting | Parameter | Measured Value | Standard Value | Error with Signs | Dimensional Accuracy |
---|
Nr.6 | Spiral | 3.18 | 3 | 0.18 | CT 4 |
| Height | 30.21 | 30 | 0.21 | CT 3 |
| Diameter-L | 14.63 | 15 | −0.37 | CT 5 |
| Diameter-M | 14.7 | 15 | −0.3 | CT 5 |
| Diameter-H | 14.65 | 15 | −0.35 | CT 5 |
Table 30.
Dimensional measurements of Nr.7 cast grain selector.
Casting | Parameter | Measured Value | Standard Value | Error with Signs | Dimensional Accuracy |
---|
Nr.7 | Spiral | 3.2 | 3 | 0.2 | CT 4 |
| Height | 30.38 | 30 | 0.38 | CT 5 |
| Diameter-L | 14.76 | 15 | −0.24 | CT 4 |
| Diameter-M | 14.71 | 15 | −0.29 | CT 5 |
| Diameter-H | 14.81 | 15 | −0.19 | CT 3 |