Development of Salt Core Use as an Alternative in Aluminum Alloy Castings.

Tülay Hançerlioğlu 1*
1 R&D Department Nemak İzmir Döküm San.A.Ş.

  • tulay.hancerlioglu@nemak.com
  • Orcid: 0000-0003-2373-4405
    Received: 6 December 2021
    Accepted: 1 June 2022
    DOI: 10.18466/cbayarfbe.1033177

Abstract

For creating complex geometric shapes in the cast part, salt was used to produce core instead of sand
which is thermo-chemical or chemical process using resin as a binder. In salt core casting, the efficiency
will be increased by reducing the core gas-induced errors in the part. The harmful effect on the
environment will be reduced with the absence of odor and smoke from the core gas. Using water in salt
core breaking instead of mechanical impact and vibration during sand core breaking will bring benefits
such as eliminating the noise source and using less energy. By eliminating the dust generated during sand
core breaking, its harmful effects on the environment will be reduced. Since the salt core can be dissolved
in water and removed from the piece without any residue, there will be no problem of sand remaining in
the sand core from time to time.

주조 부품에 복잡한 기하학적 모양을 만들기 위해 열화학 또는 수지를 바인더로 사용하는 화학 공정인 모래 대신 소금을 사용하여 코어를 생성했습니다. 염심 주조에서 부품의 코어 가스로 인한 오류를 줄임으로써 효율성이 증가합니다. 코어 가스에서 냄새와 연기가 없어 환경에 대한 유해한 영향이 줄어듭니다. 샌드 코어 파쇄 시 기계적 충격 및 진동 대신 염심 파쇄에 물을 사용하면 소음원을 제거하고 에너지를 덜 사용하는 등의 이점이 있습니다. 샌드 코어 파쇄시 발생하는 먼지를 제거하여 환경에 대한 유해한 영향을 줄입니다. 염심은 물에 용해되어 잔류물 없이 조각에서 제거될 수 있으므로 때때로 모래심에 모래가 남아 있는 문제가 없습니다.

Figure 1. Sectional view of the pump body.
Figure 1. Sectional view of the pump body.
Figure 2.2. Injection mold fixed side manufactured for salt core.
Figure 2.2. Injection mold fixed side manufactured
for salt core.
Figure 2.1. Injection mold movable side manufactured for salt core
Figure 2.1. Injection mold movable side
manufactured for salt core
Figure 3. Salt core injection molding
Figure 3. Salt core injection molding
Figure 4. Salt core laser scanning compared with 3D data model.
Figure 4. Salt core laser scanning compared with 3D
data model.
Figure 5. Salt core exterior surface crack.
Figure 5. Salt core exterior surface crack.
Figure 6. Salt core inner diameter surface crack
visible with eye control.
Figure 8. Roughness value measure from the casting part with a salt core.
Figure 8. Roughness value measure from the casting
part with a salt core.
Figure 8.1. Roughness value measure from the casting part with a 60 AFS sand core.
Figure 8.1. Roughness value measure from the casting
part with a 60 AFS sand core.
Figure 9. Inside view of salt core.
Figure 9. Inside view of salt core.
Figure 10.1. Salt core produced in low temperature and short time.
Figure 10.1. Salt core produced in low temperature
and short time.
Figure 10.2. Salt core produced in high temperature and long time.
Figure 10.2. Salt core produced in high temperature
and long time.
Figure 11.1. Tilt casting machine.
Figure 11.1. Tilt casting machine.
Figure 11.2. Tilt casting ladle.
Figure 11.2. Tilt casting ladle.
Figure 11.3. The tilt casting machine rotates 180 degrees.
Figure 11.3. The tilt casting machine rotates 180
degrees.
Figure 12. The casting part with salt core that comes out of the casting mold.
Figure 12. The casting part with salt core that comes
out of the casting mold.
Figure 13. The salt that starts to dissolve, the core and the cast part.
Figure 13. The salt that starts to dissolve, the core and
the cast part.
Figure 14. Casting part cross section.
Figure 14. Casting part cross section.
Figure 15. Polished cast part cross-section.
Figure 15. Polished cast part cross-section.
Figure 16. Cast part zoomed images.
Figure 16. Cast part zoomed images.

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