Study of Ceramic Slurries for Investment Casting with Ice Patterns

Ice patterns generated by rapid freeze prototyping or a molding process can be used to make ceramic investment molds for metal castings. Due to the use of ice, the ceramic slurries must be poured around the pattern and cured at sub-freezing temperatures. Success of this process depends greatly on the mold strength after the gelation of the slurries. This paper describes the experimental results of the mold strength after the gelation of the slurries under different compositions. The parameters considered include mixing time, alumino-silicate vs. fused silica ratio, volume of binder, and volume of catalyst. The strength of the gelled slurries is examined by breaking test bars on a four-point bending apparatus. Weibull modulus for each trial is calculated based on the breaking strength from four-point bend tests. Analysis of variance for breaking strength and Weibull analysis is performed to evaluate the significance of the effect of each parameter. The casting of a bolt is used to demonstrate that metal castings of complex geometry can be fabricated using investment casting with ice patterns.Mechanical Engineerin

Investigation of Part Accuracy and Surface Roughness in Rapid Freeze Prototyping Based Investment Casting

The study as described in this paper is aimed at investigating the dimensional accuracy and surface finish of metal parts made by investment casting with ice patterns generated by rapid freeze prototyping. The process of investment casting with ice patterns is described and contrast with conventional investment casting with wax patterns is made. The selection of binder material for ceramic slurries and the need for an interface agent to separate the ice pattern from the ceramic slurry in the mold making process are discussed. The accuracy and surface finish of ice patterns and of the metal castings are presented and discussed. The parts used in this investigation include cylinders with vertical and slant walls and a turbine impeller.The authors gratefully acknowledge the financial support from the National Science Foundation grants (DMI-0128313 and DMI-0140625) and the Research Board of University of Missouri at Rolla.Mechanical Engineerin

An Experimental and Analytical Study of Ice Part Fabrication with Rapid Freeze Prototyping

Rapid Freeze Prototyping (RFP) is a new solid freeform fabrication process that builds an ice part by rapidly freezing water layer by layer. In this paper, we will present our recent progress in the development of this novel process. An experimental system has been built for conducting the research. It consists of an XY-table and Z-stroke driven by micro-stepping motors and a water dispensing and deposition subsystem which incorporates a solenoid valve and a syringe pump placed inside a freezer. Simple heat transfer analysis is made to help select proper values of process parameters and predict part building failures. Example ice parts have been successfully built with this process. Key factors of this freeform fabrication process are identified

Study of Ceramic Slurries for Investment Casting with Ice Patterns

Ice patterns generated by rapid freeze prototyping or a molding process can be used to make ceramic investment molds for metal castings. Due to the use of ice, the ceramic slurries must be poured around the pattern and cured at sub-freezing temperatures. Success of this process depends greatly on the mold strength after the gelation of the slurries. This paper describes the experimental results of the mold strength after the gelation of the slurries under different compositions. The parameters considered include mixing time, alumino-silicate vs. fused silica ratio, volume of binder, and volume of catalyst. The strength of the gelled slurries is examined by breaking test bars on a four-point bending apparatus. Weibull modulus for each trial is calculated based on the breaking strength from four-point bend tests. Analysis of variance for breaking strength and Weibull analysis is performed to evaluate the significance of the effect of each parameter. The casting of a bolt is used to demonstrate that metal castings of complex geometry can be fabricated using investment casting with ice patterns

Determination and Improvement of Building Speed in Rapid Freeze Prototyping 514

Rapid freeze prototyping (RFP) is a solid freeform fabrication process that builds an ice part by rapidly freezing water in a layer by layer manner. One advantage of this process is the ability to build ice parts faster than other SFF processes. The factors that affect the speed of contour building and interior filling in RFP are identified. The influence of these factors is analyzed through heat transfer and material flow analyses. A model based on heat transfer analysis is proposed to determine the maximum achievable speed of contour building under stable conditions. Experiments are conducted to validate the performance of the proposed model for determination of building speed.Mechanical Engineerin

Increase of Heat Transfer to Reduce Build Time in Rapid Freeze Prototyping

Reduction of part build time in the Rapid Freeze Prototyping (RFP) process, which fabricates a 3D ice part layer-by-layer by depositing and freezing water droplets, has been achieved by increase of heat transfer. Three mechanisms have been experimentally investigated: 1) cooling the substrate, 2) use of forced convection, and 3) use of a chilling plate. Cooling the substrate is effective for parts of small heights but becomes ineffective with increase in part height. Forced convection produced desirable reduction in part build time but with the undesirable formation of frost on the built ice part. The use of chilling plate to increase heat conduction proved to be most effective. To ensure that the frozen ice from the deposited water can be easily removed from the chilling plate, various surface coats were investigated and the most effective surface coat was found to be a thin Teflon film. After incorporating the chilling plate we have successfully achieved 75% reduction in part build time.Mechanical Engineerin

Investment shell cracking

Shell cracking is the single greatest problem affecting investment casters. A clearer understanding of the factors affecting the melt profile of the wax can be gained using computational fluid dynamics (CFD) to model the interaction among 1) the thermal conductivity of the wax, 2) the thermal conductivity of the shell, and 3) the temperature of the autoclave during the autoclave de-waxing cycle. The most favorable melt profile results from a high autoclave temperature (438⁰K to 458⁰K) and saturated thermal conductivity of the shell (1.36 to 1.40 Wm⁻¹k⁻¹) in conjunction with a low wax thermal conductivity (0.33 Wm⁻¹k⁻¹). These parameters reduce the likelihood of shell cracking as a result of wax bulk expansion --Abstract, page iv

Modeling, analysis and experimentation for building ice parts with supports using rapid freeze prototyping

Rapid Freeze Prototyping (RFP) is a freeform fabrication method that freezes water droplets into ice in a layer-by-layer manner to additively create a 3-dimensional part. Each layer of a geometry is deposited and allowed to freeze before the next layer is added. Ice parts produced by RFP can be used in investment casting to replace wax patterns and in other applications which may benefit from the unconventional method of using ice as a pattern or mold. More recently, a sacrificial support material has been incorporated into RFP so that over-hung areas and complex geometries can be fabricated. The research presented in this PhD dissertation study intends to provide information about a selected support material that has been implemented into the RFP process. The work first presents an overview of the process parameters of the system and the effects they have on the overall build dimensions and surface finish. The work continues on to the investigation process of finding a suitable support material to be used in conjunction with water/ice in RFP. The work then presents a model which illustrates the interaction occurring during fabrication of the main build material (i.e. water freezing to ice) and the support material. Two types of models are derived and explained, which are thermal and concentration models. These models are derived, described in detail, and their solutions obtained by finite element analysis are given. Experimentally obtained data is compared to predictions from the thermal and concentration models. Dimensional accuracy of finished ice parts is also examined for various build parameters. Measurements of geometric features of ice parts are presented as an indication of the dimensional accuracy build capability of RFP. Surface roughness measurements are also given. Sample ice parts are shown throughout the dissertation document--Abstract, page iii