Effect of Printing Parameters of 3DP Sand Mold on the Casting Performance of ZL205A Alloy
WANG Chunhui1, YANG Guangyu1(), ALIMASI Aredake1, LI Xiaogang2, JIE Wanqi1
1.State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi'an 710072, China 2.Northwest Industries Group Co. Ltd., Xi'an 710043, China
Cite this article:
WANG Chunhui, YANG Guangyu, ALIMASI Aredake, LI Xiaogang, JIE Wanqi. Effect of Printing Parameters of 3DP Sand Mold on the Casting Performance of ZL205A Alloy. Acta Metall Sin, 2022, 58(7): 921-931.
Sand inkjet three-dimensional printing (3DP) technology is ideal for rapidly producing sand mold and sand core for complex thin-walled castings without using traditional casting flasks and patterns, as it offers high printing speed, high dimensional accuracy, good collapsibility, high productivity, and low cost. The constrained rod casting and single spiral fluidity methods were used to investigate the hot tearing susceptibility (HTS) and fluidity of ZL205A casting alloy under various printing parameters of a 3DP sand mold (furan resin content 1.5%-3.0% (mass fraction), printing layer 0.28-0.32 mm). The HTS of the ZL205A alloy first increased and then decreased with increasing resin content, whereas steadily decreased as the printing layer thickness increased. The HTS of the ZL205A alloy was mainly related to the strength of the 3DP sand mold. The fluidity of the ZL205A alloy decreased with increasing resin content and printing layer thickness. Finally, using the theoretical regression and normalization method, the regression equations between the 3DP sand mold's printing parameters and ZL205A alloy's castability were established. The optimized 3DP-printing parameters suitable for ZL205A alloy using 3DP sand mold casting were determined. The resin content was 1.5%, and the printing layer thickness was 0.28 mm.
Fund: National Key Research and Development Program of China(2018YFB1106800);Ningxia Thirteen Five-Years Major Science and Technology Project(2018BCE01001)
Fig.1 Three-dimensional printing (3DP) sand mold (a) and schematics of hot tearing susceptibility testing (unit: mm) (b), and 3DP sand mold of the single-helix fluidity testing (c)
Fig.2 Schematics of the tensile specimen of 3DP sand mold (unit: mm)
Fig.3 Macro-morphologies of ZL205A alloy hot tearing susceptibility bars prepared by 3DP sand mold with different resin contents (mass fraction) and printing layer thicknesses (Hot crackings are marked by rectangles)
Fig.4 Schematics of factors influencing the hot tearing susceptibility (a) rod length factor (flength) (b) tear location factor (flocation)
Fig.5 Variation curves of hot tearing susceptibility (Y1) of the ZL205A alloy with different 3DP printing parameters (Y1 is calculated by Eq.(1))
Fig.6 Variation curves of the mold tensile strength with different 3DP printing parameters
Fig.7 Cooling rate variation curve of ZL205A alloy in 3DP sand molds with different resin contents under the printing layer thickness of 0.28 mm
Fig.8 Macro-morphologies of ZL205A alloy fluidity specimens prepared by 3DP sand mold with different resin contents and printing layer thicknesses
Fig.9 Variation curves of the fluidity length of the ZL205A alloy with different 3DP printing parameters
Fig.10 Variation curve of the gas evolution from different resin contents for 3DP mold sand under the printing layer thickness of 0.28 mm
i
pi
qi
1
-0.257542097245903
-294046.970408271
2
-2.83015706572016
178976.497962565
3
2.45922736413675
-69271.2661368186
4
-0.363793894904688
10360.1236350591
5
-16.2692060546864
1550446.7040738
6
0.283900116701206
-3206585.50013
7
0.0108489539950024
29.3705896768819
8
118.828514840866
-30.9026912200925
9
423.402071622377
10
-1786.70014340018
Table 1 Parameter values of constants p1-p8 and q1-q10 in Eq.(2)
X1
X2
Y1
Y2
Z
Y
Y
Z*
∣Z*-Z∣ / Z
%
mm
mm
mm
%
1.5
0.28
4
1185
0.978
4.117
1193.421
1.00264
2.54
1.5
0.30
2
1175
0.959
1.813
1172.075
0.94929
0.97
1.5
0.32
0
1070
0.621
-0.275
1066.809
0.64338
1.25
2.0
0.28
50
1170
0.677
47.003
1163.537
0.67383
0.43
2.0
0.30
18
1160
0.824
23.948
1146.461
0.75106
8.88
2.0
0.32
4
1065
0.614
3.053
1081.600
0.66971
9.05
2.5
0.28
90
1105
0.257
91.541
1088.837
0.20004
22.30
2.5
0.30
50
1050
0.313
46.937
1069.904
0.39337
25.60
2.5
0.32
6
1020
0.467
6.509
1015.543
0.45033
3.50
3.0
0.28
0
1090
0.712
0.163
1100.241
0.74225
4.23
3.0
0.30
0
1080
0.682
-0.228
1086.069
0.70070
2.77
3.0
0.32
0
1060
0.621
-0.582
1045.607
0.25083
6.50
Table 2 Experimental and fitted values of the foundry properties for the ZL205A alloy prepared by 3DP sand mold with different printing parameters
Y
RMSE
SSE
R
R2
DC
Y
2.195134127
57.82336604
0.9968912799
0.9937922239
0.9937922238
Y
11.60599689
1616.389968
0.9762407960
0.9530460919
0.9530460430
Table 3 Fitted errors and correlation analyses of the foundry properties for the ZL205A alloy
Fig.11 Casting performance index of the ZL205A alloy with the different 3DP printing parameters (Z* is shown as a rainbow surface, and Z is shown as a black solid ball)
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