Investigating into casting LMPA (low-melting-point alloy) with 3D-printed mould and inspecting quality using 3D scanning
ISSN: 1355-2546
Article publication date: 30 July 2024
Issue publication date: 27 August 2024
Abstract
Purpose
Three-dimensional (3D) casting means using additive manufacturing (AM) techniques to print the mould for casting the cast tool. The printed mould, however, should be checked for its dimensional accuracy. 3D scanning can be used for the same. The purpose of this study is to combine the different AM techniques for 3D casting with 3D scanning to produce parts with close tolerance for preparing electrical discharge machining (EDM) electrodes.
Design/methodology/approach
The four processes, namely, stereolithography, selective laser sintering, fused deposition modelling and vacuum casting, are used to print the casting mould. The mould is designed in two halves, assembled to form a complete mould. The mould is 3D scanned in two stages: before and after using it as a casting mould. The mould's average and maximum dimensional deviations are calculated using 3D-scanned results. The eutectic Sn-Bi alloy is cast in the mould. The surface roughness of the mould and the cast tool are measured.
Findings
The cast tool is selected from the four processes in terms of dimensional accuracy and surface finish. The same is electroplated with copper. The microstructure of the cast tool (low-melting-point alloy) and deposited copper is analysed using a scanning electron microscope. Energy dispersive spectroscopy and X-ray diffraction techniques are used to verify the composition of the cast and coated alloy. The electroplated tool is finally tested on the EDM setup. The material removal rate and tool wear are measured. The performance is compared with a solid copper tool. The free-form customised EDM mould is also prepared, and the profile is cast out. The same is tested on the EDM. Thus, the developed path can be successfully used for rapid tooling applications.
Originality/value
The eutectic composition of Sn-Bi is cast in the 3D-printed mould using different AM techniques combined with 3D scanning quality to check its feasibility as an EDM electrode, which is a novel work and has not been done previously.
Keywords
Acknowledgements
Acknowledgements: The authors thank the Science and Engineering Research Board (SERB) – India for funding the project.
Funding: The work was supported by the Science & Engineering Research Board (SERB) – India. Grant no. (CRG/2019/001320).
Author's contribution: Mr Rishi Parvanda has done the literature review, conducted the experiments and drafted the complete manuscript. Dr Prateek Kala has proposed the experimental planning and analysis of the results and incorporated the critical changes in the manuscript.
Disclosure statement: The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.
Ethical statement: The authors ensure the originality of the article, and it is not submitted to any other journal.
Citation
Parvanda, R. and Kala, P. (2024), "Investigating into casting LMPA (low-melting-point alloy) with 3D-printed mould and inspecting quality using 3D scanning", Rapid Prototyping Journal, Vol. 30 No. 8, pp. 1675-1692. https://doi.org/10.1108/RPJ-07-2023-0230
Publisher
:Emerald Publishing Limited
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