Process capability investigation on the 3D printing technique for hybrid silica-based sands cores
Mukul Ramesh Kumar, Stefania Cacace, Maurizio Chiesa, Daniele Chiesa, Paolo Parenti
Abstract. Sand Binder Jetting is one of the most important innovations that foundry field experienced in recent years. One of the main challenges of Binder Jetting consists in the handling of the large machine volumes and in the consequent tendency to show building box inhomogeneity, in terms of performance and quality of the printed pieces. This paper presents a process capability study of an industrial sand printer, used in the field of cores for the cast iron foundry of hydraulic valves, with a focus on the part dimensional accuracy and mechanical resistance (bending strength). Printing orientation of the parts, as well as their positioning inside the building box, are considered as factors of the investigations. Results show that the printing direction is the most impactful parameters, whereas the Z oriented parts show less dimensional accuracy and the weakest mechanical resistance. XY location in the layer is also seen to vary the parts resistance, more than the parts accuracy. Part density varies by about 20% while their bending resistance of about 30% in the building box. Expressions of an existing correlation between parts resistance and part density are observed, but these are not strong enough to justify all of the observed results.
Keywords
Binder Jetting (BJ), Additive Manufacturing, Casting Sand, Density
Published online 9/10/2025, 9 pages
Copyright © 2025 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Mukul Ramesh Kumar, Stefania Cacace, Maurizio Chiesa, Daniele Chiesa, Paolo Parenti, Process capability investigation on the 3D printing technique for hybrid silica-based sands cores, Materials Research Proceedings, Vol. 57, pp 225-233, 2025
DOI: https://doi.org/10.21741/9781644903735-26
The article was published as article 26 of the book Italian Manufacturing Association Conference
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
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