Additively Manufactured Single-Use Molds and Reusable Patterns for Large Automotive and Hydroelectric Components

Henderson, Hunter B.; Stromme, Eric T.; Kesler, Michael S.; Sims, Zachary C.; Chesser, Phillip; Richardson, Brad; Thompson, Michael J.; Love, Lonnie; Peter, William; Morris, Emily; Rios, Orlando; Weiss, David

doi:10.1007/s40962-019-00379-0

Title: Additively Manufactured Single-Use Molds and Reusable Patterns for Large Automotive and Hydroelectric Components

Journal Article · Mon Oct 28 00:00:00 EDT 2019 · International Journal of Metalcasting

DOI:https://doi.org/10.1007/s40962-019-00379-0· OSTI ID:1797668

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Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Univ. of Tennessee, Knoxville, TN (United States)
Emrgy, Inc., Atlanta, GA (United States)
Eck Industries, Manitowoc, WI (United States)

Additive manufacturing (AM) has the potential to reduce costs in the casting industry, particularly for large parts (i.e., components with any dimension > 12 in.). In this study, pilot-scale production case studies of hydroelectric and automotive parts were used to evaluate two AM-enabled casting methods: the direct printing of sand molds by binder jet and printing of reusable cope and drag patterns for sand casting. An additional benefit was found when additively manufactured patterns were used in combination with heat-treat free aluminum alloys, to produce castings of complex hydrodynamic surfaces. These parts previously required production via subtractive machining due to part distortion induced by the quench step of heat treatments. The machine types used for the three case studies are sand-binder jet, high-resolution polymer fused deposition modeling (FDM), and big area additive manufacturing (BAAM) FDM in combination with CNC machining. Each method demonstrated distinct advantages over traditional casting practices in particular use cases. Single-use molds show great reductions in start-up cost to produce one-off or legacy parts, and additively manufactured impression patterns show promise for innovating the tooling design process for complex geometry and large castings.

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Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Manufacturing Office

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1797668

Journal Information:: International Journal of Metalcasting, Vol. 14, Issue 2; ISSN 1939-5981

Publisher:: Springer NatureCopyright Statement

Country of Publication:: United States

Language:: English

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