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Abstract

This review article is concerned with metamaterials, i.e. specifically engineered structures with special properties for interaction with sounds. The research on and practical design of these materials have gained momentum in the last decade, when 3D printing techniques provided the possibility to fabricate such geometrically complex structures. We briefly describe the history of research on AMMs and group them into active and passive metamaterials. For each of these groups of AMMs, we discuss the most notable construction achievements and outline the main applications. We conclude this review with a discussion of possible directions for further research and main applications of AMMs such as noise attenuation, acoustic lens, and the cloaking phenomenon.
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Authors and Affiliations

Bartłomiej Sztyler
1
Paweł Strumiłło
1

  1. Institute of Electronics, Lodz University of Technology, Poland
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Abstract

The paper presents the technology of bimetallic castings using the casting method of applying layers directly during the casting process. The bimetallic casting consists of a load-bearing part (typical casting material, i.e. gray cast iron with flake graphite) and a working part (titanium insert). The titanium insert was made by printing using the selective laser melting (SLM) method, and its shape was spatial. The verification of the bimetallic castings was carried out mainly based on metallographic tests, temperature and thickness measurements. Structure examinations containing metallographic microscopic studies with the use of a light microscope (LOM) and a scanning electron microscope (SEM) with microanalysis of the chemical composition (energy dispersive spectroscopy - EDS).The aim of the tests was to select the appropriate geometrical insert parameters for bimetallic castings within the tested range. The correct parameters of both the insert, pouring temperature and the casting modulus affect the diffusion processes and, consequently, the formation of carbides and the creation of bimetallic castings.
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Authors and Affiliations

A. Dulska
1
ORCID: ORCID

  1. Silesian University of Technology, Faculty of Mechanical Engineering, Department of Foundry Engineering, Towarowa 7, 44-100 Gliwice, Poland
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Abstract

Additive manufacturing (AM) technologies have been gaining popularity in recent years due to patent releases – and in effect – better accessibility of the technology. One of the most popular AM technologies is fused deposition modeling (FDM), which is used to manufacture products out of thermoplastic polymers in a layer-by-layer manner. Due to the specificity of the method, parts manufactured in this manner tend to have non-isotropic properties. One of the factors influencing the part’s mechanical behavior and quality is the thermoplastic material’s bonding mechanism correlated with the processing temperature, as well as thermal shrinkage during processing. In this research, the authors verified the suitability of finite element method (FEM) analysis for determining PET-G thermal evolution during the process, by creating a layer transient heat transfer model, and comparing the obtained modelling results with ones registered during a real-time process recorded with a FLIR T1020 thermal imaging camera. Our model is a valuable resource for providing thermal conditions in existing numerical models that connect heat transfer, mesostructure and AM product strength, especially when experimental data is lacking. The FE model presented reached a maximum sample-specific error of 11.3%, while the arithmetic mean percentage error for all samples and layer heights is equal to 4.3%, which the authors consider satisfactory. Model-to-experiment error is partially caused by glass transition of the material, which can be observed on the experimental cooling rate curve after processing the temperature signal.
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Authors and Affiliations

Łukasz Kowalski
1
ORCID: ORCID
Michał Bembenek
1
ORCID: ORCID
Andrzej Uhryński
2
ORCID: ORCID
Szymon Bajda
3
ORCID: ORCID

  1. Department of Manufacturing Systems, Faculty of Mechanical Engineering and Robotics, AGH University of Krakow,Al. Adama Mickiewicza 30,230-059 Kraków, Poland
  2. Department of Machine Design and Maintenance, Faculty of Mechanical Engineering and Robotics, AGH University of3Krakow,Al. Adama Mickiewicza 30, 30-059 Kraków, Poland
  3. Faculty of Metals Engineering and Industrial Computer Science, AGH University of Krakow, Al. Adama Mickiewicza 30, 30-059, Kraków, Poland
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Abstract

This paper presents the results of experiments on metallization of plastic elements produced using 3D printing technology from the light-hardened resins. The obtained coatings were bimetallic (Cu/Ni). The first step of metallization was the electroless deposition of copper. The second one was electrodeposition of nickel on the previously prepared copper substrate. The parameters of 3D prints preparation and metallization processes were deeply investigated. The etching of plastics substrates and duration of electroless metallization of 3D prints by copper were analyzed. In the next step the influence of nickel electrodeposition time was investigated. The coating were analyzed by XRD method and morphology of surface was analyzed by scanning electron microscopy (SEM). The thickness of coatings was calculated based on mass differences and measured by using optical microscopy method. The optimal parameters for both processes were specified.
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Authors and Affiliations

R. Kowalik
D. Kutyła
A. Kwiecińska
P. Żabiński
K. Kołczyk
W. Zborowski
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Abstract

Additive manufacturing in recent years has become one of the fastest growing technologies.

The increasing availability of 3D printing devices means that every year more and more

devices of this type are found in the homes of ordinary people. Unfortunately, air pollution is

formed during the process. Their main types include Ultra Fine Particles (UFP) and Volatile

Compounds (VOC). In the event of air flow restriction, these substances can accumulate in

the room and then enter the organisms of people staying there. The article presents the

main substances that have been identified in various studies available in literature. Health

aspects and potential threats related to inhalation of substances contained in dusts and gases

generated during the process are shown, taking into account the division into individual types

of printing materials. The article also presents the differences between the research results

for 3d printing from individual plastics among different authors and describes possible causes

of discrepancies.

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Authors and Affiliations

Anna Karwasz
Filip Osinski
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Abstract

This article presents a comparison of test results from two models of anti-vibration systems (I and II) made employing MJF 3D printing technology and two different materials. The research included laboratory tests and numerical simulations, assuming a linear nature of the mechanical properties for the materials and models of structures. The aim of this research was to assess the consistency between laboratory test and numerical simulation results. In addition, evaluation of the suitability of using MJF technology to produce antivibration systems was conducted. During the laboratory tests, the response of the two models of structures to vibrations generated by an exciter was recorded using a high-speed camera. Subsequent image analysis was performed using the MOVIAS Neo software. The obtained values of vibration displacements and resonant frequencies were used to validate the numerical model created in the Simcenter Femap software. Relative differences between the values of resonant frequencies obtained experimentally and through simulations were determined. In the case of the structural model I, creating its numerical model without considering the nonlinearity of mechanical parameters was found to be unjustified. The comparison of the displacements determined during numerical simulations showed relative differences of less than 16% for both models in relation to the laboratory test results. This comparison result indicates a satisfactory accuracy in simulating this parameter. An assessment of the quality and accuracy of MJF technology-produced prints, led to the conclusion that due to the formation of internal stresses during the print creation, the use of “soft” materials in this technology is problematic.
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Authors and Affiliations

Piotr Kowalski
1
ORCID: ORCID
Adrian Alikowski
1
ORCID: ORCID

  1. Central Institute for Labour Protection – National Research InstituteWarsaw, Poland
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Abstract

The paper presents the properties of plastics under the trade names of PMMA and Midas, and of Formowax, Romocast 305 and Romocast 930 casting waxes. Their effect on the quality of foundry patterns used in the manufacture of ceramic moulds for precision casting is also discussed. From the selected materials for foundry patterns, samples were made for testing using the following methods: (i) 3D printing in the case of plastics, and (ii) conventional method based on tooling in the form of metal moulds (dies) in the case of casting waxes.

The most important physico-mechanical properties of materials for foundry patterns were determined, i.e. linear shrinkage, softening temperature, relative elongation and coefficient of thermal linear expansion. Bending tests were carried out on samples of patterns printed and made in metal moulds, including determination of the surface roughness of patterns.

After the process of melting out patterns from the cavities of ceramic moulds in an autoclave, the degree of their melting out was visually assessed (i.e. the residues from pattern removal were evaluated). The ash content after burning out of foundry patterns was also determined. The conducted tests allowed comparing the important parameters of materials used for foundry patterns and assessing the suitability of selected plastics as a material for foundry patterns used in the manufacture of high-quality precision castings.

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Authors and Affiliations

A. Dydak
M. Książek
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Abstract

Investment casting combined with the additive manufacturing technology enables production of the thin-walled elements, that are geometrically complex, precise and can be easy commercialized. This paper presents design of aluminium alloy honeycombs, which are characterized with light structure, internal parallel oriented channels and suitable stiffness. Based on 3D printed pattern the mould was prepared from standard ceramic material subjected subsequently to appropriate heat treatment. Into created mould cavity with intricate and susceptible structure molten AC 44200 aluminium alloy was poured under low pressure. Properly designed gating system and selected process parameters enabled to limit the shrinkage voids, porosities and misruns. Compression examination performed in two directions showed different mechanisms of cell deformation. Characteristic plateau region of stress-strain curves allowed to determine absorbed energy per unit volume, which was 485 or 402 J/mm3 depending on load direction. Elaborated technology will be applied for the production of honeycomb based elements designated for energy absorption capability.

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Authors and Affiliations

K. Naplocha
ORCID: ORCID
A. Dmitruk
ORCID: ORCID
P. Mayer
J.W. Kaczmar
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Abstract

The anatomy of the human temporal bone is complex and, therefore, poses unique challenges for students. Furthermore, temporal bones are frequently damaged from handling in educational settings due to their inherent fragility. This report details the production of a durable physical replica of the adult human temporal bone, manufactured using 3D printing technology. The physical replica was printed from a highly accurate virtual 3D model generated from CT scans of an isolated temporal bone. Both the virtual and physical 3D models accurately reproduced the surface anatomy of the temporal bone. Therefore, virtual and physical 3D models of the temporal bone can be used for educational purposes in order to supplant the use of damaged or otherwise fragile human temporal bones.

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Authors and Affiliations

Janusz Skrzat
Matthew J. Zdilla
Paweł Brzegowy
Mateusz Hołda
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Abstract

The application of 3D printers significantly improves the process of producing foundry patterns in comparison to traditional methods of their production. It should be noted that the quality of the surface texture of the foundry pattern is crucial because it affects the quality of the casting mold and eventually the finished casting. In most studies, the surface texture is examined by analyzing the 2D or 3D roughness parameters. This is a certain limitation because, in the case of 3D printing, the influence of technological parameters is more visible for irregularities of a longer range, such as surface waviness. In the paper, the influence of the 3D printing layer thickness on the formation of waviness of the surface of casting patterns was analyzed. Three 3D printers, differing in terms of printing technology and printing material, were tested: PJM (PolyJet Matrix), FDM (fused deposition modeling) and SLS (selective laser sintering). In addition, the surface waviness of patterns manufactured with traditional methods was analyzed. Surface waviness has been measured using the Form Talysurf PGI 1200 measuring system. Preliminary results of the research showed that the layer thickness significantly influences the values of waviness parameters of the surface in the casting patterns made with FDM, PJM and SLS additive technologies. The research results indicated that the smallest surface waviness as defined by parameters Wa, Wq and Wt was obtained for patterns printed using the PJM technology, while the highest was noted when using the FDM technology.
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Authors and Affiliations

Paweł Zmarzły
1
ORCID: ORCID
Damian Gogolewski
1
Tomasz Kozior
1

  1. Faculty of Mechatronics and Mechanical Engineering, Kielce University of Technology, Poland
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Abstract

This article summarizes technical aspects of preparing printable 3D anatomical models created from radiological data (CT, MRI) and discusses their usefulness in surgery of the human skull. Interdisciplinary approach to the capabilities of the 3D printers, and the materials used for manufacturing 3D objects oriented on replicating anatomical structures has created new possibilities for simulating and planning surgical procedures in clinical practice settings.
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Authors and Affiliations

Janusz Skrzat
1

  1. Department of Anatomy, Jagiellonian University Medical College, Kraków, Poland
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Abstract

Quality of 3d model in simple way translates into quality of final product, obtained from 3d printing. 3d CAx software give possibility to create enormous number of shapes – doesn’t matter solids or surfaces. The question is where is the frontier between quality of 3d model and a value for money of the completed print? Is it always necessary to create as good model as possible? This paper will focus on preparation of 3d models, based on primitives and will show connection between quality of mesh, its size and deviations and quality of obtained samples, in same manufacturing conditions.
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Authors and Affiliations

M. Tagowski
1
ORCID: ORCID

  1. Częstochowa University of Technology, Faculty of Technology and Automation, 21. Armii Krajowej Av., 42-201 Częstochowa, Poland
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Abstract

The study aimed to develop a system supporting technological process planning for machining and 3D printing. Such a system should function similarly to the way human experts act in their fields of expertise and should be capable of gathering the necessary knowledge, analysing data, and drawing conclusions to solve problems. This could be done by utilising artificial intelligence (AI) methods available within such systems. The study proved the usefulness of AI methods and their significant effectiveness in supporting technological process planning. The purpose of this article is to show an intelligent system that includes knowledge, models, and procedures supporting the company’s employees as part of machining and 3D printing. Few works are combining these two types of processing. Nowadays, however, these two types of processing overlap each other into a common concept of hybrid processing. Therefore, in the opinion of the authors, such a comprehensive system is necessary. The system-embedded knowledge takes the form of neural networks, decision trees, and facts. The system is presented using the example of a real enterprise. The intelligent expert system is intended for process engineers who have not yet gathered sufficient experience in technological-process planning, or who have just begun their work in a given production enterprise and are not very familiar with its machinery and other means of production.
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Authors and Affiliations

Izabela Rojek
1
ORCID: ORCID
Dariusz Mikołajewski
1
ORCID: ORCID
Piotr Kotlarz
1
ORCID: ORCID
Marek Macko
2
ORCID: ORCID
Jakub Kopowski
1 3
ORCID: ORCID

  1. Institute of Computer Science, Kazimierz Wielki University, Chodkiewicza 30, 85-064 Bydgoszcz, Poland
  2. Faculty of Mechatronics, Kazimierz Wielki University, Chodkiewicza 30, 85-064 Bydgoszcz, Poland
  3. Faculty of Psychology, Kazimierz Wielki University, Chodkiewicza 30, 85-064 Bydgoszcz, Poland
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Abstract

Nowadays, it is necessary to develop a conceptual framework for analysing the relationship between the implementation of Additive Manufacturing (AM) and Supply Chain Management (SCM). In this context, a gap in the research has been observed in the new approach to designing the importance of AM in SCM. The main contribution of this paper, therefore, is a new framework to formulate the role in adopting AM in SCM. The research methodology is based on detailed literature studies of AM in relation to the SCM process within a manufacturing company, as well on a case study, namely the COWAN GmbH manufacturing company who specialise in producing homewares for motorhome enthusiasts. As highlighted in the state-of-the-art analysis, no work, currently available, supports all the features presented.
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Authors and Affiliations

Justyna Patalas-Maliszewska
1 2
ORCID: ORCID
Katarzyna Kowalczewska
3
Matthias Rehm
2
ORCID: ORCID

  1. Institute of Mechanical Engineering, University of Zielona Góra, Poland
  2. Professorship Production Systems and Processes, Chemnitz University of Technology, Germany
  3. Germany, COWAN GmbH, Germany
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Abstract

The paper presents an innovative method of creating the layered castings. The innovation relies on application the 3D printing insert obtaining in SLM (selective laser melting) method. This type of scaffold insert made from pure Ti powder, was placed into mould cavity directly before pouring by grey cast iron. In result of used method was obtained grey cast iron casting with surface layer reinforced by titanium carbides. In range of studies were carried out metallographic researches using light microscope and scanning electron microscope, microhardness measurements and abrasive wear resistance. On the basis of obtaining results was stated that there is a possibility of reinforcing surface layer of the grey cast iron casting by using 3D printing scaffold insert in the method of mould cavity preparation. Moreover there was a local increase in hardness and abrasive wear resistance in spite of the precipitation of titanium carbides in surface layer of grey cast iron. While the usable properties of composite surface layer obtained in result of use of the method presented in the paper, strongly depend of dimensions of scaffold insert, mainly parameters Re and Ri.

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Authors and Affiliations

A. Dulska
J. Szajnar
N. Przyszlak
T. Wróbel
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Abstract

The densification behavior of H13 tool steel powder by dual speed laser scanning strategy have been characterized for selective laser melting process, one of powder bed fusion based metal 3d printing. Under limited given laser power, the laser re-melting increases the relative density and hardness of H13 tool steel with closing pores. The single melt-pool analysis shows that the pores are located on top area of melt pool when the scanning speed is over 400 mm/s while the low scanning speed of 200 mm/s generates pores beneath the melt pool in the form of keyhole mode with the high energy input from the laser. With the second laser scanning, the pores on top area of melt pools are efficiently closed with proper dual combination of scan speed. However pores located beneath the melt pools could not be removed by second laser scanning. When each layer of 3d printing are re-melted, the relative density and hardness are improved for most dual combination of scanning. Among the scan speed combination, the 600 mm/s by 400 mm/s leads to the highest relative density, 99.94 % with hardness of 53.5 HRC. This densification characterization with H13 tool steel laser re-melting can be efficiently applied for tool steel component manufacturing via metal 3d printing.

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Authors and Affiliations

Im Doo Jung
Jungho Choe
Jaecheol Yun
Sangsun Yang
Dong-Yeol Yang
Yong-Jin Kim
Ji-Hun Yu
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Abstract

The article presents the results of research on selected thermal, mechanical properties, as well as the microscopic structure of filaments and details made on a 3D printer in FDM technology. The materials used in the study were PETG (polyethylene terephthalate doped with glycol) and PLA (polylactide) doped with copper. As part of the study, Differential Scanning Calorimetry (DSC) was performed in order to determine the temperatures of phase transformations and changes in melting enthalpy values of filaments before the printing process and also elements made of them. The second part of the research was electrocorrosive ageing process of printouts, carried out in the Simulated Body Fluid solution in a device generating 0.3 A direct current, voltage with value 4.3 V for the entire duration of the test, which was 720 h. After this process DSC test was conducted again. The next stage of the research was Dynamic Mechanical Analysis (DMA) of printouts before and after electrocorrosive ageing process. This test was carried out to characterize the dynamic-mechanical properties as a function of frequency, temperature and time. Additionally, microscopic analyses of the surfaces of the tested printouts were performed in order to assess the changes after electrolysis.
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Authors and Affiliations

J. Redutko
1
ORCID: ORCID
A. Kalwik
1
ORCID: ORCID
A. Szarek
1
ORCID: ORCID

  1. Czestochowa University of Technology, Faculty of Mechanical Engineering and Computer Science, Department of Technology and Automation, 21 Armii Krajowej Av., 42-201 Czestochowa, Poland
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Abstract

Progress in the industry is accompanied by the development of new materials and more efficient technological production processes. At present, additive production is becoming very attractive in all industries (research, development, production), which brings a number of advantages compared to subtractive methods (customization, production speed, control of material properties by users, etc.). The main advantage of 3D printing is the controlled deposition of material in defined places. Instead of demanding manual labour, fully automated production via computers leads to the manufacturing of complex components from materials whose production in conventional ways would be problematic or even impossible. Because these are new technologies, the main direction of research at present is to identify the basic physical properties of these materials under different types of loading.
The main goal of this article is to observe the dependence of the behaviour of the extruded material (thermoplastic reinforced with chopped carbon fibre) on the printing parameters (thickness of the lamina, the orientation of the fibres of the printed material, etc.). Based on published scientific works, it appears that these settings have a significant impact on the achieved physical properties. This is the reason why the authors decided to analyze the influence of these parameters on the basis of processed data from experimental measurements of mechanical properties in the MATLAB program. As this is FFF printing, an essential condition is to identify and specify the directional dependence of the behavior of the printed material. This physical phenomenon is a necessary condition for gradual knowledge for the purposes of a subsequent mathematical description of the material properties. According to the authors, for the purposes of modeling these materials in FEM-based programs, it is essential to define the directional dependence in the plane of the lamina.
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Authors and Affiliations

J. Majko
1
ORCID: ORCID
M. Handrik
1
ORCID: ORCID
M. Vaško
1
ORCID: ORCID
M. Sága
1
ORCID: ORCID
P. Kopas
1
ORCID: ORCID
F. Dorčiak
1
ORCID: ORCID
A. Sapietová
1
ORCID: ORCID

  1. University of Žilina, Faculty of Mechanical Engineering, Department of Applied Mechanics, Univerzitná 8215/1, 010 26 Žilina, Slovak Republic
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Abstract

The Fourth Industrial Revolution, also known as Industry 4.0, is about connecting the physical world with the virtual world in real-time. With the advent of the Fourth Industrial Revolution, manufacturing companies are introducing a number of solutions that increase productivity and personalize finished products in line with the idea of Industry 4.0. The application of, among others, the following: 3D printing, the Internet of Things, Big Data, cyber-physical systems, computing clouds, robots (collaborating and mobile), Radio-frequency identification systems, and also quality control and reverse engineering systems, is becoming popular. There are still not enough studies and analyses connected with the Polish 3D printing market, and also attempt to determine the attitude of those studies and analyses to the implementation of the Industry 4.0 conception. In connection with what is stated above, the principal objective of this paper is to determine the directions of the 3D printing industry development. In this publication, it is as well the survey respondents’ opinions relevant to opportunities and threats connected with the implementation of the Industry 4.0 conception in an enterprise are presented. The survey was conducted on a group of 100 enterprises and scientific research institutes in Poland, offering and/or applying additive technologies.
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Authors and Affiliations

Joanna Wozniak
1
Grzegorz Budzik
2
Łukasz Przeszłowski
2
Katarzyna Chudy-Laskowska
1

  1. Rzeszow University of Technology, Faculty of Management, Rzeszów, Poland
  2. Rzeszow University of Technology, Faculty of Mechanical Engineering and Aeronautics, Rzeszów, Poland
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Abstract

As a part of this work, an analysis of the current state of knowledge regarding the use of additive technology - binder jetting in the production of castings was made. The binder jetting (so-called 3D printing) has become the leading method of sand mold and core production. Within this paper types of molding and core sands with organic and inorganic binders that are and can be used in technology were analyzed. The need to carry out works aimed at developing pro-ecological molding / core sands with inorganic binders and organic binders with reduced harmfulness to the environment dedicated to binder jetting technology was noticed. The influence of technology parameters on the properties of molding / core sands and the properties of cast components was analyzed. It was shown that thanks to the unlimited shapes of the systems obtained with the use of additive technologies, it is possible to influence the rate of heat dissipation through the mold, which positively effects the process of solidification and crystallization of the castings.
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Authors and Affiliations

Dawid Halejcio
1
ORCID: ORCID
Katarzyna Major-Gabryś
1
ORCID: ORCID

  1. AGH University of Krakow, Faculty of Foundry Engineering Department of Moulding Materials, Mould Technology and Non-ferrous Metals al. A. Mickiewicza 30, 30-059 Krakow

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