Continuous production process for 3D printed ceramic foundry filters, suiting all applications

3D 打印陶瓷铸造过滤器的连续生产工艺，适合所有应用

• 批准号: 96247
• 金额: $ 35.42万
• 依托单位: CAT INTERNATIONAL LTD
• 依托单位国家: 英国
• 项目类别: Collaborative R&D
• 财政年份: 2021
• 资助国家: 英国
• 起止时间: 2021 至 无数据
• 项目状态: 已结题
• 来源: https://gtr.ukri.org/projects?ref=96247
• 关键词: Continuous; production; process; 3D; printed

Metal components are required across many sectors including aerospace, automotive, manufacturing and construction. As such, cast metals in the UK generated sales of £1.89bn in 2017 (Cast Metals Foundation, Industry Census) with a global market of £123Bn in 2019 (Grandview Research, 2020). Liquid metal is cast into different and often specific shapes and it is important these components do not have defects which could lead to catastrophic failure. Filtration of the metal can reduce imperfections/defects which in turn minimises the number of failures that are unusable. Reducing the number of components manufactured to obtain high quality usable products consequently reduces the energy inputs and carbon dioxide emissions associated with this high energy consumption sector.Metal filters are often made from ceramic materials formed around polyurethane foam, however, when fired to remove the foam and create the filter pores, toxic fumes can be emitted and there is no guarantee of pore size and reproducibility. Additionally, shrinkage when materials are fired can be problematic adversely impacting the pore size.CAT International Ltd, a leading manufacturer of foundry filters and consumables, have developed a novel ceramic formulation (covered by a patent) and process that ensure high quality, reproducible filters for use in the metal casting foundry sector (foundation industry). We will develop an Additive Manufacturing (3D printing) process and proprietary ceramic formulation (ceramic materials combined with organic resin) that can be used to fabricate the filters. We have undertaken initial work and seek to carry our further industrial research to optimise our manufacturing process and formulation and test our materials in terms of properties and user needs.By using our new innovative process, we seek to enhance performance throughout the supply chain which will minimise materials wastage associated with defective parts. This will then minimise energy usage where the same inputs can create more usable parts as a result of better liquid metal pre-processing.Our project will improve the environmental performance of a sector that uses high volumes of raw material and increasing amounts of energy. Changes to the sector as a result of the Covid-19 pandemic provide us with a chance to build back a more environmentally sustainable industry in response to UK and global priorities to reduce waste and work towards net zero emissions by 2050\.

包括航空航天、汽车、制造业和建筑业在内的许多行业都需要金属部件。因此，2017年英国铸造金属的销售额为18.9亿英镑（铸造金属基金会，行业普查），2019年全球市场为1230亿英镑（Grandview Research，2020）。液态金属被铸造成不同的，通常是特定的形状，重要的是这些部件没有可能导致灾难性故障的缺陷。金属的过滤可以减少瑕疵/缺陷，从而最大限度地减少不可用的故障数量。减少制造部件的数量以获得高质量的可用产品，从而减少了与这个高能耗行业相关的能源投入和二氧化碳排放。金属过滤器通常由聚氨酯泡沫周围形成的陶瓷材料制成，但是，当烧制以去除泡沫并形成过滤孔时，可能会排放有毒烟雾，并且无法保证孔径和重现性。CAT International Ltd是铸造过滤器和耗材的领先制造商，开发了一种新型陶瓷配方（已获得专利）和工艺，可确保金属铸造行业（基础行业）使用的高质量、可再生的过滤器。我们将开发增材制造（3D打印）工艺和专有陶瓷配方（陶瓷材料与有机树脂结合），可用于制造过滤器。我们已经开展了初步工作，并寻求进行进一步的工业研究，以优化我们的制造工艺和配方，并在性能和用户需求方面测试我们的材料。通过使用我们的新创新工艺，我们寻求提高整个供应链的性能，从而最大限度地减少与缺陷零件相关的材料浪费。这将最大限度地减少能源消耗，因为同样的投入可以通过更好的液态金属预处理生产出更多可用的零件。我们的项目将改善使用大量原材料和不断增加的能源的行业的环境绩效。2019冠状病毒病大流行对行业造成的变化为我们提供了一个机会，以重建一个更具环境可持续性的行业，以响应英国和全球减少废物的优先事项，并努力实现到2050年的净零排放。