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<p>Three-dimensional sand printing (3DSP) of molds revolutionizes sand mold casting process as it eliminates any undercut issue and gets rid of patterns. However, the inherent 3DSP high mold surface roughness is critical during transfer of liquid metal during filling stage. Besides impacting the cast part surface condition quality, it may alter filling stage because of high head loss induced by friction. In the present work, an innovative experimental setup is developed to characterize filling dynamics inside 3DSP mold. Both transient and permanent filling regimes are studied to correlate head loss to the mold “sand equivalent roughness.” The obtained theoretical roughness parameter is then discussed in regards to standard roughness parameters obtained by direct profile measurements. Additionally, optimization of the experimental setup is proposed for closer sand equivalent roughness estimation. Finally, this article provides the author analysis for better prediction of melt—3DSP mold friction during filling stage of metal casting.</p>

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Investigating major head loss in additively manufactured sand molds during casting

  • 期刊论文

  • 发表日期：

    2025年10月13日

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  • Marie Bedel,
  • Nicolas Coniglio,
  • Hervé Combeau,
  • Jérémie Bourgeois,
  • Mohamed El Mansori

摘要

Three-dimensional sand printing (3DSP) of molds revolutionizes sand mold casting process as it eliminates any undercut issue and gets rid of patterns. However, the inherent 3DSP high mold surface roughness is critical during transfer of liquid metal during filling stage. Besides impacting the cast part surface condition quality, it may alter filling stage because of high head loss induced by friction. In the present work, an innovative experimental setup is developed to characterize filling dynamics inside 3DSP mold. Both transient and permanent filling regimes are studied to correlate head loss to the mold “sand equivalent roughness.” The obtained theoretical roughness parameter is then discussed in regards to standard roughness parameters obtained by direct profile measurements. Additionally, optimization of the experimental setup is proposed for closer sand equivalent roughness estimation. Finally, this article provides the author analysis for better prediction of melt—3DSP mold friction during filling stage of metal casting.