Revolutionary Improvements for Investment Castings via 3D … · 2020. 3. 22. · Investment...
Transcript of Revolutionary Improvements for Investment Castings via 3D … · 2020. 3. 22. · Investment...
1 Herald Square | Fairborn, Ohio 45324 | 937-322-3227 | www.PERFECT3D.com
© 2018 Renaissance Services Inc.
Revolutionary Improvements for Investment Castings
via3D-Printed Ceramic Tooling and Process Aids
Investment Casting Institute – Technical Conference & ExpoOctober 23, 2018
ICI Technical Conference & Exposition
Presentation Outline
• Tooling/Process Aids for Investment Casting
• Ceramic Additive Manufacturing
• Case Study: 3D-Printed Ceramic Mold
• Summary
2
ICI Technical Conference & Exposition
Tooling from Ceramic Additive Manufacturing
3
Focus is 3D-printed ceramic components to support investment casting
MoldsCores Filters
ICI Technical Conference & Exposition
Why 3D-Printed Ceramics?
4
Provide capabilities not available via traditional manufacturing processes
MoldsCores Filters
Complexity of newcore designs that surpass capability
of injection molding
Small quantity of cores needed during casting development
Part designs that challenge the dipping
of traditional 3D-printed wax patterns
Desire to provide a consistent flow
system and material cleanliness
Avoid inclusions introduced by
traditional foam filters
ICI Technical Conference & Exposition
Ceramic Additive Manufacturing
5
Designing Cores, Molds, Filters for
3D Printing Process
ICI Technical Conference & Exposition
Ceramic Additive Manufacturing
6
Mixing Special Materials for Ceramic 3D
Printing
ICI Technical Conference & Exposition
Ceramic Additive Manufacturing
7
3D Printing the Ceramic
Components
ICI Technical Conference & Exposition
Ceramic Additive Manufacturing
8
Cleaning the 3D-Printed
Ceramic Components
Renaissance Services Confidential Information
ICI Technical Conference & Exposition
Ceramic Additive Manufacturing
9
Firing the Ceramic
Components for Investment
Casting
ICI Technical Conference & Exposition
Ceramic Additive Manufacturing
10
Performing 3D Inspection on the Ceramic Components
ICI Technical Conference & Exposition
Focus for 3D-Printed Cores and Molds
Complexity
Volume/Quantity
CeramicAdditive
Manufacturing
Traditional Ceramic Injection &
Wax Patterns
High
High
11
Low
Best fit for 3D printing are parts that are low volume and/or high complexity
ICI Technical Conference & Exposition
3D-Printed Ceramic Filters
12
• Improve capture of material contaminants
• Reduce inclusions introduced from foam filter tentacles
• Ensure consistent flow rate for mold fills
Foam Filter Engineered Filter
ICI Technical Conference & Exposition
Start with Customer’s ‘Finished Part’ CAD Model
Modify Customer Supplied Data to Develop Core Model
Create Model for 3D Printing
Build Support Geometry and Nest on Platform
Establish “Slice File” for Individual Layers
Print Parts onPlatform
Check & Inspect Parts
Remove & CleanParts
3D-Printed Ceramic Cores
13
ICI Technical Conference & Exposition
Traditional Investment Casting Flow
14
Injecting WaxPatterns
Coating withCeramic
Firing CeramicMold Tree
RemovingCeramic Mold
Cleaning the Castings
MachiningPattern Die
Coating withSlurry
AssemblingWax Mold Tree
Pouring MetalInto Mold Tree
Melting OutWax
ICI Technical Conference & Exposition
Investment Casting with 3D-Printed Molds
15
RemovingCeramic Mold
Cleaning the Castings
Pouring MetalInto Mold Tree
3D PrintCeramic Mold
ICI Technical Conference & Exposition
Case Study: F108 Gearbox Housing
16
Part Number: 335-300-402-0A-357 Aluminum Casting
ICI Technical Conference & Exposition
F108 Housing Removed from Service
17
Start with part removed from airplane to enable reverse engineering
ICI Technical Conference & Exposition
proprietary proprietary
proprietary
Procure Article Scanning CAD Model Mold Model Mold Design
3D Print Molds Raw CastingFired Mold Pour Metal Breakout
Overview of Rapid Casting of F108
18
From condemned part without a TDP to new raw casting in 28 days
ICI Technical Conference & Exposition
3D-Printed Ceramic Mold Components
19
Complete set of mold tree components created via 3D printing
ICI Technical Conference & Exposition
F108 Gearbox Housing Clean-Up
20
The raw casting from the ‘tool-less mold’ -- foundry: PCC Structurals
ICI Technical Conference & Exposition
Summary
21
Eliminate non-recurring core die tooling cost
One week from design to first cores compared to multi-month conventional process
Comparable to conventional cores; ability to rapidly iterate designs days versus months
None required, saving time and money; “CAD as tooling” highly flexible rapid response
Eliminate wax dietooling cost and eliminate wax patterns
From mold design to casting in 30 days compared to at least 12 month conventional cycle
Castings comparable to conventional; no issues with broken wax patterns that cause casting scrap
None required, saving time and money; “CAD as tooling” highly flexible rapid response
Comparable to current conventional filter cost, depending on size and application
Capacity sufficient to meet foundry demands withdelivery comparable to conventional filters
Tightly controlled flow rates compared to conventional results; stopped all impurities versus 40% inclusions for conventional filters
None required; 3D-printing enables on-demand filters designed to meet specific foundry needs
Molds
Cores
Filters
Cost Impact Cycle Time Performance Hard Tooling3D-Printed Ceramic Products
PERFECT-3D Division
1 Herald Square Fairborn, Ohio 45324
937-322-3227 www.PERFECT3D.com