comparison of effectiveness of primecast and …...comparison of effectiveness of primecast and pmma...
TRANSCRIPT
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Comparison of Effectiveness of Primecast and
PMMA Additive Manufacturing Processes to produce
patterns for Investment Casting of Ti6Al4V and Al
206
N P Nkhasi, W B du Preez, J G van der Walt
Centre for Rapid Prototyping and Manufacturing
Central University of Technology, Free State
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OVERVIEW
• Introduction
– Additive Manufacturing
– Investment Casting by AM
• Methodology
– Building of Patterns
– Metrology of Patterns
• Results and Discussion
• Conclusions
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Introduction
Investment casting is an old process
AM patterns without tooling (Time and cost saving)
More complex patterns produced
Durability of the a pattern
In this study a comparison was done on patterns built by PrimeCast and
PolyMethyl Methyl Acrylate (PMMA) respectively, which were produced using
two types of AM technology. The focus of this study is a field in which little
work has been done.
This paper only deals with pattern production
This comparison of the two types of AM patterns is expected to assist the
foundry industry in achieving the most beneficial investment casting results
when using either of these AM technologies.
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Introduction…Additive Manufacturing Process
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Introduction…Investment casting by AM technology
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Methodologyproject plan
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Materials and Methodstandard test part with features
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Materials and Method…building of PrimeCast
• Laser sintering process (CUT)
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Materials and MethodHow a laser sintering work
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Materials and Method…
building of PMMA
• Binder Jetting (VUT)
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Materials and MethodHow a binder jetting work
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Materials and Method…Metrology of Patterns
Two patterns, one each of PrimeCast and PMMA, were scanned at Stellenbosch
University (SU) using a General Electric Phoenix V|Tome|X L240 / NF180 Micro-
CT scanner.
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Materials and Method…Metrology of Patterns
• Object attached to rotational
stage
• Object exposed to X-ray
source
• Absorbed radiation
measure with detector
• X-rays are taken from
different angles
• 3D reconstruction
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Methodology
pattern to CAD comparisonReconstruction was done with system supplied Datos
reconstruction software
The results of the micro CT scanner were analyzed using Volume
Graphic VGStudio Max 2.1 software.
The best fit alignment was used for this study. Once the two
models were aligned, a simple 3D comparison option
automatically created a colored view showing all dimensional
difference between the two models.
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Materials and Method…Mould making
• Mould making in three weeks
• Pattern assembly
Gating for
Titanium alloy
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Materials and Method…Mould making and Casting
Gating for
Aluminium alloy
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Materials and Method…Mould making..
• Successive stages of dipping and stuccoing
• Repeated until required shell thickness
Face coat secondary coat back-up coat
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Materials and Method…Casting
On completion of the coating the pattern was removed by
melting in a steam autoclave, and the ceramic shell was fired
prior to casting.
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Results and Discussion
pattern to CAD comparison
• Differences represented by colours
• Green (best fit)
• Yellow (Pattern larger)
• Blue (Pattern smaller)
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Results and Discussion
pattern to CAD comparisonPrimeCast
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Results and Discussion
pattern to CAD comparisonPMMA
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Conclusions
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Conclusions
Accuracy PrimeCast PMMA
Straightness (Cubes, square base) Very accurate accurate
Repeatability (Cubes, Free-form) Very accurate Very accurate
Perpendicularity ( Rectangular Protrusion, Rectangular hole) accurate accurate
Angularity ( Pyramid, wedges ) accurate accurate
Symmetry ( Half sphere, Free-Form ) Very accurate Not accurate
Non-constant sloping profile ( Free-form (Conical), Free-form (Sinkhole)) accurate accurate
Circularity ( hollow cylinder) accurate accurate
Flatness accurate Not accurate
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Thank you
Contact details
Name of presenter : Nthateng Nkhasi
Cel.: 078 316 8881
E-mail: [email protected]
www.cut.ac.za | Bloemfontein (051) 507 3911 | Welkom (057) 910 3500