fpic june 2, 2017 terry senish – director of technology ... · cast alloys used in the fluid...

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How to use advanced software and 3D Printing to create high quality castings for the Fluid Power industry

FPIC June 2, 2017 Terry Senish – Director of Technology Application

© Copyright 2016 The ExOne Company


Company Overview

© Copyright 2016 ExOne


Additive Manufacturing Technologies



Fluid Power- Typical sand cast components

• Pump components

• Compressor components

• Impellers

• Valve bodies/spools

• Hydraulic & Pneumatic valves

• Cylinder Housings

• Large castings

• Complex castings



Cast alloys used in the fluid power industry Carbon & Low

Alloy Tool Steel P-H Stainless

Austenitic Stainless

Martensitic Stainless

Nickel Base Alloys

Cobalt Base Alloys

Aluminum Brass & Bronze

1018 (WCC) A-2 15-5 303 (CF16 Fa) 410 (5350G) Hastelloy B (N7M) Cobalt 3 (Stellite

3) 319 (SAE

326) C836 (85-5-5-5, B62, SAE 115, Leaded Red Brass)

1020 (WCC) A-6 17-4

(CB7CU) 304 (CF8) 416 (5394B)

Hastelloy C (CW2M)

Cobalt 6 (Stellite 6)

356 (SAE 323, 326)

C862 (SAE 423, High Strength Yellow Brass, 90,000 Tensile Manganese Bronze)

1025 (WCB) D-2 25-5 (CD 4) 310 (CK20) 420F (CA40F) Inconel 600

(CY40) Cobalt 12 (Stellite

12) 357 (SAE

357)


1030 D-7 316L (CF3M) 431 (5353B) Inconel 625

(CW6MC) 535 Almag


1040 H-13 316 (CF8M) 440C (5352C) Incoloy 825 713

Tenzaloy C873 (Everdure, 4951, Silicon Bronze)

1045 M-2 347 (CF8C) 440F (5362) Monel A C875 (SAE 500, SAE 64, 13B, Silicon Brass)

1050 M-4 Alloy 20 (CN7M) 442 (CB-30) Monel E C905 (88-10-0-2, Tin Bronze, Gun Metal)

1141 O-1 Carpenter 20 CB3 CZ-100 C907 (89-11, SAE 65, Tin Bronze)

4130 O-6 Nitronic 50 C922 (88-6-2-4, Leaded Tin Bronze)

4140 S-7 HP (ASTM A297) C952 (85-3-9, SAE 415A, #18, Aluminum Bronze 9A)

4150 T-15 C954 (81-44-11, SAE 415C, Aluminum Bronze 9D)

4340 Federalloy (I-848A, Non-leaded Brass)

6150 Beryllium Copper (ASTM B196 C17200)

8615 8620 8630

52100


All capable of being cast using 3D Printed molds & cores


Fluid Power- Typical foundry issues / 3DP solutions

Problems/Issues 3DP Advantages and Solutions


• Patterns req. time/cost • Zero or Negative Draft • Core assembly, time • Core parting lines, flash • Core shift, scrap • Re-Designs • Gas, core venting • Thin walls • High complexity • Chills • Surface defects, veining • Accuracy issues • Mold assembly issues

• 100% Patternless- quick lead time • Lighter castings, quick mold design • Quick assembly, reduced labor • Single pc, no flash, no shift, better

balance • Simultaneous versions /quick revisions • Low LOI, 3D venting capability • Unique gating implementation • Complexity is ~free • 3DP chill molds • Sand or additive additions • Near net casting


Improved design and engineering software Tools

CAD systems -Catia -Siemens NX -PTC Creo -SolidWorks -Solid Edge -Autodesk AutoCAD


Analysis systems • -Novacast- NovaFlow&Solid

• -Magmasoft Magma5

• -ESI ProCast

• -EKK

• Altair


Software calibration, validation and testing Macro/Micro shrinkage predictions vs. actual, CT & RT

• Learn to trust your software tools

• Adjust s/w for both alloy and sand type


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Software calibration, validation and testing Macro shrinkage predictions vs. actual cut up


• Macro shrinkage

• Micro shrinkage

• Metal velocities

• Turbulence

• Residual stress analysis

• Per alloy chemistry

• Fill time

• Solidification time

• Temperature profile

• Pouring temp and min/max ranges


Software Implementation Solidification modeling and analysis


Choose the least of two evils with Natural Solidification


Software Implementation Casting Orientation


Improved surface finish -sand and binder technology



Foundries use a variety of additives for various reasons. Additives that are currently available from ExOne are: • Mg Inhibitor (Potassium Tetraflouroborate) • *Veinseal™ • *Black Iron Oxide • *Zircon (10%) * - Currently only available through ExOne PSC

Improved surface finish -Additives


Improved surface finish

• Sand type

• Layer thickness

• Mold wash

• Flow rate

• Metal turbulence vs. tranquil fill



Improved Surface finish- Mold Wash

• Flow coat

• Brush coat

• Spray coat

• Zircon, Graphite

• Alcohol base

• Water base



Fluid Power – Centrifugal casting

• 400-1800 RPM

• Grey Iron

• 1390°C–1430°C

• Up to 60G force

• High Strength

• High Soundness


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Improved accuracy -Non traditional orientations and complex cores

Alignment locators for high dimensional accuracy

Blind risers for efficient feeding 1pc Vented & undercut core


Cost Reduction -Fluid power software/3D printing design benefits

• 3 cores reduced to a 1pc assy.

• 70% scrap reduced to <1%

• Less assembly time

• Less flash

• Less cleaning time

• Better quality

• Less overall cost $$



Silica Sand 3D Printed Cores


Case Study -Speed 3D Mold, 2535lbs/1150Kg. – 7 Days

• Reduction



Castings Made From Silica Molds/Cores


Large Segmented Cores and Molds



Typical Mold Assembly -cylinder housing


Consult with our Experts. Invest in an ExOne system or simply have ExOne manufacture a part for you.

ExOne The Americas MID-ATLANTIC 127 Industry Boulevard North Huntingdon, PA 15642 USA +1 877 773 9663 MIDWEST 2341 Alger Drive Troy, MI 48083 USA +1 248 740 1580 SOUTH 7409 Railhead Lane Houston, TX 77086 USA +1 281 931 0011

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www.ExOne.com +1 877 773 9663

fpic june 2, 2017 terry senish – director of technology ... · cast alloys used in the fluid...

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