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Foundry Daily News - GIFA 2019

GER - GIFA 2019: ASK Chemicals presents its binder technologies for additive manufacturing processes

ASK Chemicals presents its solutions for 3D sand printing at GIFA 2019 from 25 to 29 June 2019. The Hilden-based company's 3D binder technology combines print head compatibility, dimensional accuracy and productivity.

3D sand printing itself is not a novelty for foundries; though for a long time it has only been used for the production of prototypes and small series. Dr. Jens Muller, Global Head of R&D and  Innovation  at  ASK  Chemicals  explains, “Withthe  development  of  ever  faster  printers, especially in recent years, 3D sand printing offers foundries completely new possibilities and opportunities.Of course, binder technology has to be developed further, especially for these new  productive  systems.  Iam  therefore  very  pleased  that  we  will  be  able  to  present  new solutions for both inorganic and organic sand core production at GIFA 2019.”

A new requirement profileWith 3D sand printing using the powder binder jetting process, production of sand cores using contour-forming models and core tools is eliminated. The geometry of the sand cores is initially developed digitally based on CAD models. Next, the recoater applies a layer of a few hundred micrometers of quartz sand fully automatically. Then the binder liquid is selectively applied to the  sand  bed  via  the  print  head. The process  of  layered  sand  application  by means of  the recoater  and  selective  binder  input  via  the  print  head   is  repeated  according  to  the specifications of the digital CAD model. Finally, the binder-free support sand is removed, and the printed component may betaken to a post-curing process.

The compatibility and durability of the print head components along with the chemical components of the binder fluid areas critical to achieving success as the application and dripping behavior of the fluid. This is collectively referred to as “print head compatibility”. The physical and chemical properties of the binder  fluid  play a crucial role in this process. The physical effects during selective binder input onto the sand bed, such as the migration of the fluid into the unprinted areas of the support sand, must be understood and controlled in order to ensure a high dimensional stability and low finishing cost of the sand cores produced. “Of course, 3D binders still also have to meet high thermal stability requirements to withstand the stresses during the casting process,” explains Dr. Müller.

New solutions for new requirementsThe development of NOVASET 3D, a phenolic resin binder for cold curing, has reduced the laborintensive  finishing  effort  and  drastically  improved  the  process  efficiency  over  standard binders. NOVASET 3D has a low veining tendency and guarantees clean casting surfaces for all types of casting.

The inorganic two-component system INOTEC 3D, consisting of an INOTEC 3D printing fluid and an INOTEC 3D promoter, is applicable for hot-curing additive manufacturing processes. “As a productive inorganic binder system, INOTEC 3D standsfor zero emissions during core productionand core  storage  and  when  using  the  sand  cores  in  the  casting  process”, emphasizes Dr. Christian Appelt, Global Business Manager Inorganic Binder Systems at ASK Chemicals. Further advantages are the low finishing effort of the sand cores produced, which lead  to  castings  of  high  dimensional  accuracy  and  surface  quality  due  to  the  high  thermal stability. Above all, INOTEC 3D supports current trends in the engine casting segment of the light metal casting industry.

A special highlight at this  year's booth will be the live demonstration of the inorganic binder INOTEC 3D inorganic binder on the new voxeljet VX1000-S printer.


Source: ASK

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