22-23#02 Additively Manufactured Lost Polymer Casting Process
Principal Investigators: Ismail Fidan, Fred Vondra, Mohammad Alshaikh Ali, Tennessee Tech University
Steering Committee Chair: Marshall Miller, 3D Systems
Lost foam casting uses polystyrene patterns which are consumed by molten metal, overcoming many traditional sand-casting limitations, but still poses challenges in patternmaking. Investment casting, similar to lost foam, uses wax patterns coated to form ceramic shells for casting. Additive manufacturing has been utilized for creating complex expendable patterns for both sand and investment casting and has been used to develop patterns from decomposable materials using the material extrusion process. However, there is a lack of research for manufacturing industries to start utilizing the material extrusion process in their casting methods.
The purpose of this project was to test different material extrusion parameters to generate expendable patterns to produce castings.
Library Paper Number: Coming Fall 2026
Webinar Link: Coming 2026
17-18#04 Effect of Solution Heat Treatment Time on 356 Fatigue Properties
Principal Investigators: Dave Weiss, Vision Materials; Chris Barnes, Caterpillar, Inc.
Steering Committee Chair: Geral Gegel, Materials & Process Consultancy; Brian Began, Foseco
Mechanical properties of sand cast aluminum castings can exhibit wide variation even when the same alloy is used. Best practices to achieve maximum properties encompass a combination of foundry practice (proper metal handling, fluxing, degassing, and filtration), microstructural improvements (grain refining, modification, solidification rate, heat treatment). There has been a lot of work done on these effects on the mechanical properties of 356 aluminum alloy but limited on fatigue properties and using non-standard processes.
The purpose of this project was to quantify the impact that solution heat treatment time has on the fatigue properties of 356 aluminum alloys.
Library Paper Number: Coming Fall 2026
Webinar Link: Coming 2026