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An investigation on the suitability of layer manufacturing methods for rapid tooling development in investment casting of light metal alloys
Author(s)
Deez, Brent Steven
Date Issued
2010
Type
Thesis
Publisher
Cape Peninsula University of Technology
Abstract
The research presented in this report focuses on Investment Casting capabilities for light metal alloys in
South Africa and forms part of the Advanced Manufacturing Technology Strategy's (AMTS): Light Weight
Metals flagship programme.
The research is centred on the suitability of rapid prototyping (RP)/Iayer manufacturing (LM) methods to
produce patterns for the investment casting of aluminium (AI), magnesium (Mg) and titanium (Ti) alloys,
together known as Rapid Investment Casting. Three core RP technologies are investigated namely:
Three Dimensional Printing - Drop-on-Bed from Z-corporation, Three Dimensional Printing - Drop-on-
Drop from ThermoJet - 3D Systems and Selective Laser Sintering from EOS.
Various RP/LM processes are discussed in detail and highlight the technologies selected in this study. A
standard benchmark part, adapted from the European project framework FP6, designed and utilised in
similar studies is used as the basis for the research.
The Investment Casting process is discussed fully and compared to the Rapid Investment Casting, listing
both the advantages and disadvantages of the above mentioned methods.
In addition a special study has been conducted on investment casting of large components using layer
manufactured patterns. This study not only helped to establish and validate the shrinkage value
calculated for the aluminium castings but also showed substantial capability lacks in SA foundries to
handle this type of components, which are by definition most often of high added value.
South Africa and forms part of the Advanced Manufacturing Technology Strategy's (AMTS): Light Weight
Metals flagship programme.
The research is centred on the suitability of rapid prototyping (RP)/Iayer manufacturing (LM) methods to
produce patterns for the investment casting of aluminium (AI), magnesium (Mg) and titanium (Ti) alloys,
together known as Rapid Investment Casting. Three core RP technologies are investigated namely:
Three Dimensional Printing - Drop-on-Bed from Z-corporation, Three Dimensional Printing - Drop-on-
Drop from ThermoJet - 3D Systems and Selective Laser Sintering from EOS.
Various RP/LM processes are discussed in detail and highlight the technologies selected in this study. A
standard benchmark part, adapted from the European project framework FP6, designed and utilised in
similar studies is used as the basis for the research.
The Investment Casting process is discussed fully and compared to the Rapid Investment Casting, listing
both the advantages and disadvantages of the above mentioned methods.
In addition a special study has been conducted on investment casting of large components using layer
manufactured patterns. This study not only helped to establish and validate the shrinkage value
calculated for the aluminium castings but also showed substantial capability lacks in SA foundries to
handle this type of components, which are by definition most often of high added value.
Additional information
Thesis (MTech (Mechanical Engineering))--Cape Peninsula University of Technology, 2010.
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200652125_Deez_BS_Mtech_Mech_Eng_2010_20122169.pdf
Description
Thesis
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137.19 MB
Format
Adobe PDF
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