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Rapid casting of complex impeller based on 3D printing wax pattern and simulation optimization

  • Donghong Wang
  • Anping DongEmail author
  • Guoliang Zhu
  • Da Shu
  • Jinyu Sun
  • Fei Li
  • Baode Sun
ORIGINAL ARTICLE
  • 68 Downloads

Abstract

Rapid casting is the product of digital, information, and optimization of casting technology. It mainly includes rapid prototyping and virtual manufacturing. In order to shorten the production cycle of a stainless steel closed impeller casting, the wax pattern was made by high impact polystyrene (HIPS) with a selective laser sintering and photosensitive resin with stereolithography (SL). In order to prevent the formation of shrinkage defects, different gating systems designed to examine the molten metal flow and solidification behavior during the pouring and solidification process. The results show that pouring temperature is 1550 °C and pouring speed is 0.75 m/s, which is favorable for filling impeller castings, and can avoid casting defects. The optimized gating system prevented surface shrinkage and interior defects. The optimized gating systems have been verified by experiment, and the rapid casting has been realized based on 3D printing wax pattern and simulation optimization. This rapid casting can reduce processing time and costs, and enhance casting quality in the foundry industry.

Keywords

Rapid casting Stainless steel impeller Shrinkage porosity Numerical simulation Rapid prototyping 

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Notes

Funding information

This work was financially supported by The Major State Basic Research Development Program of China (2016YFB0701405) and National Natural Science Foundation of China (51705314, 51771118, U1760110). The authors gratefully acknowledge the financial supports from the National Industrial Basis Improvement Project under Project (TC160A310-12-1) and The 13th Five-year Major Project of Aero Engine and Gas Turbine of China (2017-VII-008). The Science and Technology Committee of Shanghai Municipality (Grant Nos. 16DZ2260602) are gratefully acknowledged.

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Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  • Donghong Wang
    • 1
    • 2
  • Anping Dong
    • 1
    • 2
    Email author
  • Guoliang Zhu
    • 1
    • 2
  • Da Shu
    • 1
    • 2
    • 3
  • Jinyu Sun
    • 4
  • Fei Li
    • 1
    • 2
  • Baode Sun
    • 1
    • 2
    • 3
  1. 1.Shanghai Key Lab of Advanced High-temperature Materials and Precision Forming, School of Materials Science and EngineeringShanghai Jiao Tong UniversityShanghaiChina
  2. 2.State Key Laboratory of Metal Matrix Composites, School of Materials Science and EngineeringShanghai Jiao Tong UniversityShanghaiChina
  3. 3.Materials Genome Initiative Centre, School of Materials Science and EngineeringShanghai Jiao Tong UniversityShanghaiChina
  4. 4.School of Materials EngineeringShanghai University of Engineering ScienceShanghaiChina

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