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Light-Weighting Technologies for High-Performance Ductile Iron Sand Castings

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There have been recent advances with high-strength high-ductility alloys and 3D (dimensional) sand printing additive manufacturing technologies. These advances make for original equipment manufacturer casting design engineers to come up with newer, innovative design solutions. Similarly, light-weighting technologies coupled with integrated computational materials engineering (ICME) tools and latest strain-life fatigue data optimize the process of casting configurations. This paper discusses thin-wall casting designs and optimization process with case studies, including the effective use of the ICME tool, casting process modelling, and toolingless 3D printed sand additive manufacturing processes. The approach of taking current legacy cast parts while utilizing thin-wall technologies is discussed within the case studies. Studies also cover casting conversion opportunities for competing materials and processes: steel fabrications, steel castings, forgings and aluminium castings for high-performance applications.

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Author acknowledges the research support from American Foundry Society as well as the work of engineers at PDA LLC in the areas of design of casting, risering and gating system, casting process simulation, FEA and fatigue life estimation on case studies presented in this paper.

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Correspondence to Jiten Shah.

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This paper is an invited submission to IJMC selected from presentations at the 2nd Carl Loper 2019 Cast Iron Symposium held September 30 to October 1, 2019, in Bilbao, Spain.

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Shah, J. Light-Weighting Technologies for High-Performance Ductile Iron Sand Castings. Inter Metalcast (2020).

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  • simulation
  • strain-life fatigue
  • ICME
  • 3D sand printing
  • additive manufacturing
  • optimization