Preliminary Agenda Abstracts TUESDAY, AUGUST 23, 2022, con’t.
10:20 a.m. – 10:50 a.m. ICI Intern Project Report Nolan Sykes, Concurrent Resources LLC
10:50 a.m. - 11:20 a.m. Evaluation of Printed Wax Pattern Molds Tom Mueller, Mueller Additive Mfg Solutions Elvira Stesikova, BASF Forward AM The use of printed investment casting patterns has almost
universally changed the way that prototype investment castings are created. Eliminating the need to first create tooling has enabled manufacturers to make prototypes faster and at lower cost and allowed the evaluation of multiple alternative designs before making the large investment in tooling.
In addition,
by using printed patterns, investment casting can be a cost- effective means for producing low numbers of metal parts. Previously, the cost of tooling prevented investment casting from being a viable option. However, for nearly all types of printed patterns, a slightly
different casting process is required which is more difficult and more expensive than that used for molded wax patterns. Unfortunately, these process modifications make it difficult for a foundry to run a mix of printed and molded wax patterns. Once the first coat of the shell is applied, all shells look alike, and it can be very difficult to keep track of which shells use which casting process. As a result, it can be difficult to use printed patterns for more than a few prototype castings. The recent development of AM materials with both high
heat deflection temperatures and high strength have enabled the possibility of printed wax pattern tooling. By printing the mold rather than the pattern, wax patterns could be molded, avoiding the need to use a different casting process. Compared to the traditional metal, 3D printed materials typically have a much lower coefficient of thermal conductivity resulting in slower cooling, longer cycle times and higher cost of molded patterns. To resolve the slow cooling issue, cooling lines and even conformal cooling lines can be incorporated into the mold design to increase production and lower the cost. Printed wax pattern molds could significantly lower the
cost of patterns when more than a few patterns are required as well as eliminate the difficulty in casting presented by printed patterns. This paper presents the results of a case study to evaluate the potential for printed wax pattern molds.
EVENT SPONSOR
11:20 a.m. – 11:50 p.m. Shifting the Engineering Focus of Back-up System Design, George Salomon & David Scott, Nalco Water – An Ecolab Company, Booth No. 320 Sam Scott, Chromalloy Castings, Tampa As investment casting foundries strive to improve the manufacturing process and reduce cost, the need to increase throughput without compromising shell integrity is a common area of interest. Reducing the amount of time required to dry shells, increasing shell thickness and uniformity per dip, and using regional refractory flours in the slurry formulation are some of the benefits that can be gained using the latest modified colloidal silica binder for backup slurries. In this presentation, we aim to present data corroborated by foundry trials demonstrating increased shell room throughput, achieved through back up dip reduction and decreased shell dry time.
11:50 a.m. – 12:30 p.m. LUNCH - Disneyland South Ballroom
12:30 p.m. – 1:00 p.m. Autoclave Technology Michael Kugelgen, MK Technology GmbH, Booth No. 308
• How does a steam autoclave really work • Relation between temperature and pressure and the best way to ramp it up
• Pressure release, what we have to respect • Best results with filled and unfilled waxes and shells with seal coat
• How to handle prototype parts and what is the difference to wax
1:00 p.m. – 1:30 p.m. A Scabbing Defect Investigation Andy Bomberger, Tech Cast LLC.; Chris Whitehouse, 3M Technical Ceramics Inc., Booth No. 320 A not uncommon shell condition causing casting defects is referred to as scabbing, where early dips loose adhesion with the backup shell. This condition was extensively studied at Tech Cast using ICI Process Control Seminar techniques and a full factorial four factor two level experimental design. Shell properties were semi-quantitatively inspected and measured for approximate surface area in order to determine their severity. Shell strength and permeability data was measured at 3M Midway to confirm shells built in the test cell were equivalent to shells built in the production cells. The results of this study should be helpful for any foundry seeking solutions to shell conditions and resulting cast metal defects.
1:30 p.m. – 2:00 p.m. An Investigation into Thermal & Mechanical Stresses on an Investment Cast Shell Gerald Richard, MAGMA Foundry Technologies, Inc., Booth No. 234 Investment Casters have a very challenging feat of
22 ❘ June 2022 ®
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