Effect of Printing Parameters of 3DP Sand Mold on the Casting Performance of ZL205A Alloy

doi:10.11900/0412.1961.2021.00293

Acta Metall Sin

2022, Vol. 58

Issue (7): 921-931 DOI: 10.11900/0412.1961.2021.00293

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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.

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Abstract

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.

Key words: 3DP (three-dimensional printing) technology sand mold casting ZL205A aluminum alloy hot tearing susceptibility fluidity

Received: 16 July 2021

ZTFLH:

TG245

Fund: National Key Research and Development Program of China(2018YFB1106800);Ningxia Thirteen Five-Years Major Science and Technology Project(2018BCE01001)

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	Chunhui WANG
	Guangyu YANG
	Aredake ALIMASI
	Xiaogang LI
	Wanqi JIE

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https://www.ams.org.cn/EN/10.11900/0412.1961.2021.00293 OR https://www.ams.org.cn/EN/Y2022/V58/I7/921

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 (f_length) (b) tear location factor (f_location)

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

Table 1 Parameter values of constants p₁-p₈ and q₁-q₁₀ in Eq.(2)

X₁	X₂	Y₁	Y₂	Z	Y $1 *$	Y $2 *$	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 $i *$	RMSE	SSE	R	R²	DC
Y $1 *$	2.195134127	57.82336604	0.9968912799	0.9937922239	0.9937922238
Y $2 *$	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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