Development of an Innovative Casting Process using 3D Sand-printing

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Additive manufacturing is a cutting edge technology that is revolutionizing the manufacturing industry. Its application to metal casting has the potential to transform the metal casting process. The application of additive manufacturing for the development of new gating systems for casting of copper-based alloys will present a significant advance over the existing process.In the metal casting process, molten metal flows in the mold cavity through sprue, runners and gates. The molten metal surface can get oxidized due to contact with air and moisture and generate oxide films. The rate of oxide formation increases with molten metal turbulence. The turbulence can cause defects such as surface oxides, oxide inclusions, sand inclusions, blowholes and bubbles. These defects are detrimental to mechanical properties and can lead to premature failure of the components.The turbulence caused by high molten metal velocity can be avoided by proper mold design and control of metal flow. The aim of this project is to effectively control the metal flow by designing a gating system using 3D sand printing (3DSP) for casting of copper-based alloys. The casting products made using this innovative process will possess significantly improved quality. This will lead to growth in revenue of the industrial partner as well as employment opportunity for highly skilled manpower at this Canadian operation.