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Mueller, T. J.; Andre, L. Performance of long thin printed cores in aluminum castings

It has been 15 years since printed sand molds and cores viable for a wide range of alloys came onto the scene. Since then, the value of using printed sand molds and cores in product development and in low volume manufacturing has been demonstrated many times over. As a result, most sand foundries have had some experience with printed cores and molds and have used them to create prototype castings. While the use of printed cores with thicker sections has proven viable and is in common use, there was little known about the casting performance of long, thin printed cores. It was uncertain whether they would be strong enough to withstand the forces exerted by the flow of metal during filling. It was also uncertain whether they could adequately vent gases generated during the casting process. This paper presents the results of tests in which 36 cored castings were created using printed sand cores. The cores ranged in length from 2 inches to 12 inches and in diameter from 0.25 inches to 0.875 inches. Castings were examined to evidence of deflection and inadequate venting.

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