Metal-Monolithic Ceramic/Metal Composite Castings Produced Using 3D Printed Sand Molds and Cores

A.P. Druschitz, C.B. Williams, B. Wood
Virginia Tech,
United States

Keywords: 3D printed sand, casting, metal-monolithic ceramic/metal composites


Monolithic ceramic and/or metallic objects can be embedded into metal castings using 3D printed sand mold and core technologies. The resulting composite castings can have a combination of mechanical and/or physical properties that cannot be obtained in a single material component. Lattice structures are lightweight and have desirable energy absorbing characteristics since energy is “slowly” dissipated as the structure collapses or fractures. Dissipation of energy over a “long” period of time is desirable for many types of structures, such as automobile crush zones or blast doors, since it reduces the likelihood of occupant injury. However, lattice structures do not have inherently high penetration resistance since the structure is largely empty space. To improve penetration resistance, it is desirable to embed hard and/or strong, monolithic inserts into a lattice structure. 3D printed sand molds have been designed to allow the incorporation of monolithic ceramic and/or metal objects into the mold and, subsequently, these objects become embedded in the final metal casting. Two examples of innovated component concepts are described in this paper, one that has a combination of high energy absorbing capacity plus high penetration resistance and a second that exhibits tensegrity behavior.