Abstract
The authors focus on current problems faced by manufacturers using additive cores in the production of critical steel castings. These problems include, in addition to high cost, high risks of surface casting defects and low process environmental friendliness. The aim of the work is to theoretically substantiate the selection of organizational and technical solutions that minimize these risks specifically for the production of a particular enterprise. To achieve this, possible directions for finding a solution were identified, including: the 3D printing technological regime; the material of the additive core; the coating of the core's working surface in contact with the molten metal. An information and analytical review of open sources describing experience in solving the problem in these directions was conducted. Ultimately, the sol-gel method was chosen as the basic approach for further development. A model stage-by-stage representation of the future technological scheme for forming an effective coating on the working surface of the additive core was formulated, and the necessary prerequisites for the successful application of the sol-gel method for forming a ceramic coating on the surface of an additive foundry core were theoretically demonstrated. This method allows minimizing the risks of defects and increasing the environmental friendliness of producing critical steel castings with complex geometry and thin walls. The obtained results are currently undergoing experimental verification to refine the parameters of the technological scheme and for subsequent implementation in the enterprise's existing production.
Keywords:
industrial 3D printer, additive casting core, critical steel casting, surface defects, environmental friendliness, core print surface coating, sol-gel method, process additives