Helping to keep casting at the forefront of technology

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1 Helping to keep casting at the forefront of technology With the development over the last couple of decades of a wide range of additive layer manufacturing (ALM) technologies, rapid prototyping has become a recognised method for the creation of both aesthetic and functional components. It now plays an integral part in the development process of new designs and concepts. Recent improvement in machines and materials has led to these technologies being accepted as faster and more cost effective routes for the manufacture of custom, low volume or series production of parts over traditional manufacturing methods. Known as rapid manufacturing, industry sectors that are adopting these processes include aerospace, automotive, motorsport, jewellery, architecture, medical, dentistry and consumer products, to name just a few. Selective laser sintering (SLS) and direct metal laser sintering (DMLS) are two ALM technologies that generate parts in a choice of materials direct from CAD data, without the investment in time and money of conventional tooling. The principles of SLS and DMLS are the same; 3D CAD data of a new product or prototype component is sliced into layers, and the powder sintered (melted) layer by layer by a computerdirected infra-red laser. Additional powder is deposited on top of each solidified layer and again sintered, building the part up in cross sections. When the part is complete, the build chamber is allowed to cool and the component removed. These are WYSIWYG processes, where the virtual model and the physical model are identical in dimension and geometry. Materials available for SLS include nylon, glass-filled nylon and polystyrene; with bronze, stainless steel, cobalt chrome and maraging steel for DMLS. Selective laser sintering The selective nature of the SLS process allows extremely complex geometries to be achieved without compromising on functionality, with the unsintered or loose material simply being blasted away with an air gun and recycled for future use. This makes it both economical and environmentally friendly. The process is self-supporting as the surrounding powder acts as a bed for the component, thus enabling parts to be nested together, allowing the optimum number of parts to be built at any one time. This differs from stereolithography (SLA) as this process requires a removable lattice around the part to support areas that would otherwise deform during the build process. SLS provides the highest level of functionality combined with speed that is currently available. There are two SLS materials suited for use in casting processes: nylon and polystyrene. A nylon part is used as a master pattern for sand casting, from which a two-part sand mould can be created for the molten metal to be poured into. A split or parting line has to be strategically created around the nylon part to allow the mould to be formed. Care must be taken in the design of the mould, using a two or multiple part mould box arrangement (cope and drag), to allow any internal, tapered or undercut features to be replicated in the mould, while still allowing the pattern to be removed. These features may necessitate the need to use further internal cores. Rapid manufacturing used in a medical application 148 FTJ June 2008

2 Rapid Prototyping for joins and post-assembly, thereby dramatically increasing their functionality. A wheel part produced using the SLS process The sand mould itself is usually destroyed on removal of the metal casting. For multiple castings, further moulds can be created using the existing master pattern and mould box arrangement. SLS polystyrene parts can be used, similar to traditional waxes, in investment casting (also known as lost wax casting), which is suitable if you want multiple metal parts quickly, without having to invest in tooling. The polystyrene part is mounted on a sprue and multiple parts can be built up as a tree, which is then repeatedly dipped into a ceramic slurry and then sand, and dried in a hot air process, producing a shell thick enough to withstand the receiving of molten metal. The tree is then placed in a furnace and the polystyrene (or wax) melts out of a gate that has been left on the part, leaving a hollow shell for the liquid material to be poured into. The polystyrene part can only be used in this process once, hence it is known as a sacrificial part. The use of polystyrene is beneficial in that the parts are easier to handle, harder to damage and stiffer than wax. Polystyrene can also be used with plaster casting, enabling a wider range of metals to be cast than with wax. The gates and supports can be designed in CAD and built directly with the part, making it all in one piece, thereby speeding up the pattern manufacture further and reducing opportunities for errors. There are several major advantages in using the SLS process, the first being the quick turnaround; from receipt of 3D CAD data, parts can be built in as little as three to five days and shipped directly to the customer or foundry. In addition, the process is extremely price-competitive compared to more traditional manufacturing techniques. Complexity of design and geometry is irrelevant, enabling intricate details to be easily replicated and previously impossible structures and forms created. Furthermore, some of the world s largest laser sintering machines, from EOS GmbH, enable parts to build in a single piece up to 700x380x580mm, reducing the need Direct metal laser sintering DMLS technology was originally developed to create complex cores and cavities for the prototype tooling industry. The initial machine (EOS M250) and material (bronze DM20) provided significant benefits compared with other rapid prototyping technologies at this time, and were the right answer for the quick production of a small series of parts. However, the ability to produce production-tooling inserts was never demonstrated with the initial machine. With the introduction of a new machine (EOS M270) with a new type of laser and new materials, it is now possible to use this technology for the manufacturing of smarter production inserts for plastic, ceramic, metal injection moulding and diecasting. Not only can high strength and hardness tool steel be used, but extra features such as conformal cooling, which will enable a more uniform distribution of temperature inside the inserts, can be added in the design of the tool at no extra cost. Shorter lead-times, increased productivity and better part quality can now be reached with the DMLS inserts. DMLS tools can be used in investment casting when complex geometries and multiple quantities of a part are required. However, if smaller quantities are required, or the geometry is less complex, production of the part in the desired material can be a more costeffective route using DMLS as the direct manufacturing method. With only a modest amount of machining and finishing required, and 98% of the powder not used to make the part is recycled, the process is extremely economical. One notable feature of DMLS is that it is possible to create a part that has both external and internal complexity in one go. Not only does this mean that you can create highly functional parts, but you can potentially combine what would have been several parts into one, saving manufacture cost, reducing assembly time and increasing reliability. The main downside to DMLS is that whilst it can make a vast range of complex forms, it cannot yet make absolutely any geometry. The 3T produces functional prototypes, aesthetic models and low volume production components using SLS and DMLS technologies. Fast, flexible and costeffective manufacturing methods, they generate parts in a choice of materials direct from CAD data, without the investment in time and money of conventional tooling. Complex geometries can be achieved with the unsintered or loose material simply being removed and recycled for future use, making it economical and environmentally friendly. Their highly trained engineers are experts in generating the best surface finish and mechanical properties achievable, and skilled model-makers produce finished models that are comparable to the final manufactured item. Remaining unchallenged as the UK s largest SLS provider, thee company is now leading the way in the supply of metal parts using DMLS. Its consultative approach to doing business ensures customers always get the best quality, service and delivery, whilst reducing time and cost to market. 3T is Certified ISO9001:2000. FTJ June

3 to downsides, offering enormous benefits for low volume production parts. Whichever casting process is used, there will always be a shrinkage factor involved. The master model/pattern or tool cavity will need to be scaled up by a certain percentage, depending upon the intended production material to allow for shrinkage in the metal during the cooling process after casting. Therefore, parts produced using the SLS and DMLS processes are built with an extra percentage added on to compensate for the shrinkage this can be done in-house by CAD engineers who manipulate the data before the part is put onto the machine to build. A full-set insert produced using DMLS melting process means that certain geometries need to be supported, hence the structures incorporated to support the component during the build process have to be subsequently removed, which can cause challenges in surface finish and post-finishing. However, these difficulties can be minimised by the skill of the manufacturer. There is a size limitation of about 220 x 220 x 200mm, and if the part is particularly solid, then there can be some distortion due to residual stresses. Again, these can be minimised by a skillful operator. Overall however, the process has very many more upsides Summary Rapid prototyping gives engineers and designers a faster route through the testing and approval processes to final production. SLS and DMLS offer accurate parts that are both complex and functional in extremely short lead-times when compared to other more traditional techniques. Advances in machines and materials mean that these technologies are increasingly becoming the cost-effective manufacturing methods of choice for many companies, opening up many more opportunities for casting and tooling. 3T RPD Ltd. Tel: +44 (0) ; fax: +44 (0) ; post@3trpd.co.uk FTJ June 2008

4 Rapid prototyping Save time and money whilst increasing accuracy The prototyping service we offer is sub-contracted to Lost Wax Developments Ltd in Kidderminster, UK. It allows our customers, who are considering using aluminium high-pressure diecastings, the opportunity to see and feel what the casting will be like at a fraction of the cost of going to a new high-pressure diecasting tool. The prototype is produced using the lost wax method and has the benefit of speed and cost saving as well as letting the customer work with a dimensional accurate component before committing to diecastings. Richard Taylor, Taylor Group Diecastings Ltd, Dundee, Scotland ( Vanguard Foundry s markets require several prototype castings for simultaneous testing and subsequent small batches for field testing. It is essential that these first-series castings accurately mirror the prototypes. The prototype method must allow for easy design modification. For this reason Vanguard opted for a rapid pattern production process. CAD data is used to simulate casting production and then to produce the pattern equipment. This enables the company to produce prototypes in five days from receipt of CAD data and be in a position to produce series production from the same pattern equipment immediately on approval of the prototype test data. As Vanguard s customers are at the forefront of continuous product performance development, the demand for prototype and small batch product is still growing. John Willetts, Vanguard Foundry, Stourbridge, West Midlands ( Foundry Trade Journal asked some foundries about the rapid prototyping service they offer their customers. P I Castings Ltd of Altrincham, Cheshire has been involved with rapid prototyping since 1986 following the first stereolithography demonstration in Europe. It is now one of just a few of the investment casting companies in the UK which has its own RP machine on site - a 3D Systems Thermojet. This is used to make wax models, which can then be turned into investment castings in stainless steel, low alloy steels, nickel and cobalt alloys, aluminium, brass or bronze, for high quality engineering, medical, aerospace or defence applications. The company is equally expert in the use of QuickCast and selective laser sintered models and has recently completed over 100,000 ( 130,000) worth of castings for the Boeing 787 Dreamliner and over 40 different types of casting for the Joint Strike Fighter wind tunnel model. Rapid prototype castings with a poured weight of over 75kg have been made for a military application, these having to be right first time and fully released to flight standards. Brian Mills, P I Castings Ltd, Altrincham ( We offered rapid prototyping as a service after I had attended a seminar and demonstration on laser sintering at the Telford campus of Wolverhampton University. I was particularly interested in using the process to produce graphite dies, which could be used for producing prototype or low volume castings in zinc alloy. Alan Carter, McDonald Diecasting Ltd ( Maycast-Nokes is able to offer rapid prototype cast parts via two distinct routes. The first is using Thermojet waxes or QuickCast patterns to make an investment/lost wax casting. These parts can be cast in a variety of aluminium alloys or steel alloys. The second route is to use an SLA model (watershed or equivalent) as a pattern to make a precision sand casting in aluminium. Both of these routes offer the advantage of no tooling costs with the benefit of having a cast component available in a short time frame from the 3D model being available. Stainless steel castings for aircraft landing gear being x-rayed in P I Castings NDT department Dave Blower, Maycast-Nokes Precision Engineering Ltd, Halstead FTJ June

5 From metal powder to quality tooling For the past four years the Innovative Product Development Centre (IPDC) within the Department of Engineering and Technology at The University of Wolverhampton, England, has been working with the toolmaking and casting sectors throughout the UK to implement innovative net-shape tooling solutions. Dr Mark Stanford fills in the details. The primary activity within the IPDC is to consider process enhancement and productivity improvements through the ability to produce highperformance tooling direct from metal powder. The IPDC has been in the unique position within the UK of evaluating and disseminating the capabilities and merits of direct metal laser sintering (DMLS) technology using an EOSINT M250 Extended metal sintering machine and, more recently, by using the latest EOS M270 equipment. These machines use a laser to sinter layers 20 microns thick of nickel bronze, steel or titaniumbased metal powder in order to create metal parts or tools. This layer thickness, coupled with the 100 micron diameter focused laser from the M270, has led to exceptional part detail resolution and enhanced surface finish. Layered build-up The layered build aspect of producing tooling means that complex interior forms can be produced that will enhance cycle times in near net Typical DMLS tool for diecasting shape production processes. For example, bespoke cooling channels for each tool cavity can be created that follow or conform to the die surface as opposed to the use of conventional straight drilling of these channels. Improved heat transfer characteristics from conformal cooling channels can remove hot spots within tooling by acting as localised heat sinks thereby promoting directional solidification, reducing shrinkage defects and enhancing the quality of the cast product. Cooling channels can now be made that run between and around ejector-pin holes and other obstructions within impression tooling. Larger cooling galleries that are not necessarily circular in cross section, can be specifically designed to promote turbulent flow thereby optimising heat transfer characteristics from tool to cooling fluid. Long, slender cores and deep, narrow ribs can also be cooled efficiently as cooling passages as small as 1mm diameter can be produced. In this instance, when a liquid cannot be pumped through small cooling DMLS facility within the Innovative Product Development Centre passages, compressed air at low pressure has been found to impart the desired cooling characteristics in order to sustain the required production rates. The net result of employing conformal cooling is that the overall solidification time associated with the casting process is reduced and productivity is improved, by up to 40% in some instances. Also, control over material solidification provides the opportunity to produce otherwise difficult to cast components that suffer from feeding problems synonymous with isolated thick cross sections. Reduced production times Rapid technologies such as DMLS are renowned for offering reduced production times for prototype manufacture of discrete parts. DMLS can therefore be used to reduce lead times for tooling production. With lower-cost tooling being offered from abroad, the casting sector needs to compete for orders on issues other than tooling costs and part piece price. In many cases orders can be won by offering production parts delivered in days not weeks. Work undertaken within the 152 FTJ June 2008

6 IPDC has led to the optimisation of the DMLS process that minimises downstream activities required to put sintered tooling into production. Typically, a process of building onserts as opposed to inserted impression tooling, removes the need to machine impression pad holes in die bolsters. Fixturing developed for the EOS M250 Ext sintering machine has allowed standard Hasco/ DME plates to be used, which can be pre-datumed, feed and ejector holes pre-drilled and the DMLS impression built directly over the pre-drilled holes. These developments have led to proven time-scales from completed tooling design to the manufacture of high-pressure diecast components being measured in hours not weeks. One case study showed a leadtime to be reduced by 70%. Single-day manufacturing As the adoption of unit die concepts provides the opportunity to implement single minute exchange of dies (SMED), the IPDC has proven that single-day manufacture of tooling (SDMT) is now possible. Historically, rapid tooling (RT) technologies have been considered to be only suitable for prototype manufacture. However, recent material developments associated with DMLS technology can offer the opportunity to generate fully hardened series production tooling from a Maraging tool steel that can be post age hardened to ~50Rc. This exciting capability now offers the associated benefits of DMLS coupled with the ability to sinter full series production tooling leading to a full range of e-manufacturing capabilities. Dr Mark Stanford PhD BEng CEng MIET, assistant director Innovative Product Development Centre, Reader in Engineering, The University of Wolverhampton, School of Engineering & the Rapid Prototyping High-pressure zinc diecastings and tooling made from Direct Metal 20 sintered material Built Environment, Department of Engineering and Technology. Tel: +44 (0) ; fax: +44 (0) ; m.stanford@wlv.ac.uk STRIKO U.K. LIMITED A MEMBER OF THE STRIKOWESTOFEN GROUP OF COMPANIES MELTING & HOLDING EQUIPMENT WESTOMAT DOSING FURNACES GAS & ELECTRIC CRUCIBLE FURNACE MAMMUT-WETRO RANGE OF SILICON- CARBIDE AND GRAPHITE CRUCIBLES SCHAFER FOUNDRY METAL TREATMENTS Striko U.K. Limited Units 23 & 24, Jupiter Business Park, Hixon, Staffordshire, ST17 0PF Telephone: +44 (0) Fax: +44 (0) striko-uk@strikowestofen.com Web: FTJ June

7 Rapid Prototyping One of The Manufacturing Engineering Centre s (MEC) most successful services relates to metal casting, the modern equipment, based on the block investment casting process, delivering high-quality precession metal castings valued by its customers. Two machines are at rapid metal casting manufacturing and research disposal in MEC. The MCP vacuum rapid investment casting machine assisted by over-pressure melts up to 1200 C, having a maximum sizes of 500mm with a total volume of metal up to three litres. The second unit is a Schultheiss GmbH centrifugal vacuum casting machine melting up to 1800 C, this equipment is used for smaller castings. Talented and committed patternmakers, engineers and researchers have developed timesaving techniques to produce metal parts in aluminium, zinc, copper and ferrous alloys in exceptionally short time scales - in many cases within a week from receipt of 3D CAD file to ready metal part. The main pattern making processes available are selective laser sintering (SLS) and Thermojet, Zinc alloy casting with 0.25mm walls and aspect ratio thickness to height of 50 Multiple advantages of rapid prototyping Frank D Marsh, marketing director of The Manufacturing Engineering Centre at Cardiff University, Wales, highlights some expertise and hardware available at the facility. only their accuracy limits the precision of the castings. The overall final accuracy conforms to IT12/13 with the surface roughness average Ra in the range of 0.005mm. Recent research has been carried out in microscale casting and improving microstructure. This has allowed MEC s team to cast wall thickness down to 0.25mm with aspect ratio thickness/height of 60. Mechanical properties of its castings are similar to those obtained by diecasting. SLS overview capabilities MEC s expertise in using the polystyrene-based SLS material Castform for production of investment casting patterns is one of its strongest manufacturing services. Its Castform patterns have superior investment casting properties, simply by being the closest rival to pure wax. They do not leave traces of ash and are mild to the shell or block during the burnout stage, delivering unchanged dimensions, surface roughness and shape. Another advantage is their comparatively low price and short delivery time sometimes by the next day. A DTM 2500 CI SLS machine is used to produce patterns with maximum sizes of 400mm and accuracy conforming to IT12/13. MEC s highly skilled patternmakers may overcome this size limit by joining and finishing in such a way which cannot be noticed on the final castings. To achieve better surface finish, resolution and accuracy in crucial areas, patterns can be made by combining with Thermojet inserts as local substitutions. Extensive research in the Castform patternmaking area has been performed for the past seven years by MEC s research team and is closely related to casting practise. This allows fulfilment of even the most demanding customer requirements regarding sizes, shapes, accuracy and delivery time of Castform patterns for rapid prototyping metal casting. The Manufacturing Engineering Centre, Cardiff University. Tel: +44 (0) ; fax: +44 (0) ; manufacturing@cf.ac.uk Complex shape aluminium alloy casting with intricate features made from Castform pattern Precision zinc alloy casting made from Thermojet pattern 154 FTJ June 2008

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