Binder jetting 3D printing process optimization for rapid casting of green parts with high tensile strength

Binder jetting 3D printing is a rapid,cost effective,and efficient moulding/core making process,which can be applied to a large variety of materials.However,it exhibits a relatively low green-part strength.This may cause the collapse of the printed parts during de-caking and the pick-up procedure,especially in the case of small-scale structures,such as thin walls,tips,and channels.In this work,polyvinyl alcohol(PVA)was used as the additive in coated sand powder.By exploiting the binding effect between the two composites(thermoplastic phenolic resin and PVA)triggered by the binder,bonding necks firmly form among the sand particles,improving the green-part strength of the coated sand printed parts.Experiments based on the Taguchi method were used to investigate the relationship between the process parameters and the green-part tensile strength.The following set of optimal process parameters was identified:50wt.%alcoholicity of the binder,75%binder saturation,0.36 mm layer thickness and 4.5wt.%PVA content.Further,the effect of such parameters on the green-part tensile strength was determined via statistical analysis.The green part of an engine cylinder head sand pattern with complex cavity structures was printed,and the green-part tensile strength reached 2.31 MPa.Moreover,the ZL301 aluminum alloy impeller shape casting was prepared using sand molds printed with the optimal process parameters.The results confirm that the proposed binder jetting 3D printing process can guarantee the integrity of the printed green parts and of small-size structures during de-caking and the pick-up procedure.Furthermore,the casting made from the printed sand molds exhibits a relatively high quality.

Study on the Influence of Alkali Activator Solutions on Strength Improvement of Pozzolan Calcium Hydroxide Binders

Alkali activated binder, commonly known as geopolymer cement, has replaced Portland cement in the production of mortar and concrete globally over the past few years. The density, particle size distribution, and specific surface area (SSA) are important physical parameters affecting strength and durability of alkali activated binders. This study carried out tests for physical and chemical properties of the natural pozzolan and calcium hydroxide and then determines the influence of alkali solution (sodium silicate and sodium hydroxide) on strength development of natural pozzolan calcium hydroxide binders. The particle size distribution (PSD), relative densities (RD), and specific surface areas (SSA) of powder natural pozzolan and calcium hydroxide materials and for the mixture of natural pozzolan and calcium hydroxide were determined by using Blaine air permeability apparatus. The optimum proportion of 75% natural pozzolan and 25% calcium hydroxide was obtained which produces the compressive strength of 7.5 MPa at 28 days cured paste. The mixture of natural pozzolan and calcium hydroxide were further grinded at three different finenesses and the particle size gradation, specific densities, specific surface areas and mean particles sizes for the mixture were determined. The compressive strength of alkali activated binders increased with increasing curing period and fineness. The maximum compressive strength for 28 days cured specimens was 26.1 MPa which was obtained at a solution of 8 moles sodium hydroxide concentration. The test results showed that natural pozzolan materials can be used to make geopolymer binders for mortars and concretes. The geopolymer binders for mortars and concretes reduce green gas emission from cement factory but also it can be used to produce durable mortar and concrete with comparable strengths with mortars and concrete made from conventional Portland cement.

Effects of binder components and PVA modifier on bonding performance of phosphate binder for sand core-making

A type of heat-curing phosphate binder was proposed,and orthogonal experiments based on the tensile strength of sand samples determined that the optimal composition of the binder was phosphoric acid:water:aluminum hydroxide:magnesium oxide:boric acid=300:70:60:9:8.Adding 10%polyvinyl alcohol(PVA)solution during the sand mixture process can significantly improve the 24 h tensile strength of sand samples.When adding 30 g phosphate binder and 8 g 10%PVA solution,the initial tensile strength of the sample is 0.76 MPa,the room temperature tensile strength is 2.29 MPa,and the 24 h tensile strength is 1.73 MPa.The heat-curing modified phosphate sand mold has high tensile strength and low gas generation,which can meet general casting production requirements.

Realizing of Optimization of Binder Backfill Material Under Certain Strength with Fuzzy Sets

The main factors deciding the compressive strength of binder backfill body are tailing density and binder dosage in binder backfill materials. Based on the antecedent of certain pulp density, the method of increasing the tailing density and reducing the binder dosage, or the manner of cutting down the tailing density and gaining the binder dosage are taken to guarantee the strength of backfill body. The problem that should be solved is how to determine the tailing density and the binder dosage rationally. This paper tries to realize the correct selection of the tailing density and the binder dosage in computer with the method of fuzzy mathematics.

Effect of molasses binder on the physical and mechanical properties

Molasses was used as an alternative binder to the bentonite binder. The change in moisture absorption by pellets prepared with different iron ores and different molasses contents were investigated. Iron ore properties exerted the major effect on pellet behavior and final pellet quality. The absorbed moisture content of pellets prepared without binder, bentonite-added pellets, and molasses-added pellets were in the range of 7.72%–9.95%, 9.62%–10.84%, and 6.14%-6.69%, respectively. The wet pellet compressive strength of molasses-added pellets(43–230 N/pellet) was superior to that of bentonite-added pellets(9.47–11.92 N/pellet). The compressive strength of dried molasses-modified pellets increased to 222–394 N/pellet, which is currently the highest value achieved for dried pellets.

Effects of Water/Binder Ratio on the Properties of Engineered Cementitious Composites

The effects of water/binder ratio （w/b） on the toughness behavior, compressive strength and flexural strength of engineered cementitious composites （ECC） were investigated. The w/b ratios of 0.25, 0.31, 0.33 and 0.37 were selected and the specimens were tested at the ages of 7 d and 28 d. The experimental results showed that there was a corresponding increase in first cracking strength, modulus of rupture, compressive strength and flexural strength with the decrease of w/b. Within the w/b range of 0.25-0.37, higher w/b was found to have improved effects on deflection, strain hardening index and toughness index of ECC. In the permission of meeting the requirement of compressive strength grade, selecting higher w/b in mix design will help to obtain robust ECC.

Modification of inorganic binder used for sand core-making in foundry practice

With modified water glass as binder and the introduction of micro silicon powders into the coremaking process,an improvement was made to the tensile strength and collapsibility of the sand core.The potassium hydroxide,sodium hexametaphosphate and white sugar were applied as the modifiers of water glass.The optimum proportion of the modifiers was determined through the combination of single factor test and orthogonal test.The optimum proportion of water glass,potassium hydroxide,sodium hexametaphosphate and white sugar is 1000:40:5:5(wt.).In terms of weight,modified binder and micro silicon powders accounted for 2%and 0.6%of sand,respectively.The sand core was hardened by going through a warm core box process,in which the temperature of core box was 150°C,and the compressed hot air was blown at 120°C for 40 s under a pressure of 0.2 MPa.As for the sand core bonded with modified water glass,the tensile strength is 2.46 MPa at room temperature(σ0)and 2.49 MPa at 25°C and 40%RH for 24 h(σ24),which are 2 times more than that with unmodified binder.The bonded strengths of sand core are increased as a result of the reaction between-OH groups from addition of potassium hydroxide and SiO2 particles widely distributed in the sand core.Comparing with the sand core bonded with unmodified water glass,the high temperature residual tensile strength(σr)of sand core bonded with modified water glass under 600°C for 5 min,is sharply reduced from 0.20 MPa to 0.01 MPa.By the comparison with unmodified water glass,the dynamic viscosity of the modified water glass and the flowability of molding sand using modified water glass are increased from 74 mPa·s and 2.15 g to 80 mPa·s and 2.21 g,respectively.As revealed by FT-IR analysis,new groups including PO3-,PO43-,and Si-O-C appear in the molecular structure of modified water glass,which are beneficial to the collapsibility of sand core.

Ceramic Setting Phosphate Binders for Bonding Refractory Concretes

The ceramic setting binders obtained by means of the raw mix mechano-chemical processing(mechanical dispersion and chemical interaction processes combination), used for bonding refractory concretes, become more available with a subsequent increased interest in their properties because they develop initial strength during a heat up of the units within 8-10 h, in contrast to 24 h after placement for high Al_2O_3 cements(HAC). This strength development enables high temperature processing units to be relined with minimum turnaround time, thus providing a favored cost/performance ratio. The present paper identifies the predominant phosphate phases responsible for developing good mechanical-strength properties of zirconia and alumina concretes bonded with mechano-chemical binders. It sets out the colloid and crystalline phases resulted from interphase interaction that provide the basis for high concentrated bonding suspensions(HCBS) technology useful to the refractory industry.

An improved sodium silicate binder modified by ultra-fine powder materials

This paper presents a new method of modifying sodium silicate binder with ultra-fine powders. The sodium silicate binder modified by ultra-fine powder A and the organic B can reduce the addition amount of the binder. The results indicate that the 24 h strength has increased by 39.9% at room temperature and the residual strength has decreased by 30.7% at 800℃, compared to the conventional sodium silicate. An available material to improve the moisture resistance was also found by adding about 2% more inorganic C, and it can increase the moist strength by 20%. In the end, the microanalyses are given to explain the modifying machanism, i. e., the ultra-fine powder A can refine the sodium silicate binder to avoid holes in the binder bond, which can increase the 24 h strength at room temperture, and can lead to more cracks in the bond after the molding sand is heated to 800℃. This is because of the stress caused by the new eutectic complex of modified sodium silicate binder.

WATER-BASED BINDERS USED IN PROCESS FORMAKING AUTOMOBLE FILTER PAPER

A method for making a automobile filter which includes impregnating a filter paper with a cross-linkable binder composition is discussed in the article. The water-based binder comprises a latex containing 80 wt% acrylic acid in the latex solids, and 20 wt% melthyl methacrylate, the binder also contains 5 parts of a cross-linking resin per 100 weight parts of latex solids and 5% parts of catalyst for the cross-linking resin based on the weight of the cross-linking resin. 4 wt% water-based polymer emulsion, on a solids basis, which is used to impregnate filter paper and rigidify it. Such impregnated filter paper has good dry and wet tensile strength and stiffness. The method has no impairing to the environment.

Effect of nano TiO_(2) and SiO_(2) on gelation performance of HPAM/PEI gels for high-temperature reservoir conformance improvement

Nanoparticles have been widely used in polymer gel systems in recent years to improve gelation performance under high-temperature reservoir conditions. However, different types of nanoparticles have different effects on their gelation performance, which has been little researched. In this study, the high-temperature gelation performance, chemical structure, and microstructure of polymer gels prepared from two nanomaterials (i.e., nano-SiO_(2) and nano-TiO_(2)) were measured. The conventional HPAM/PEI polymer gel system was employed as the control sample. Results showed that the addition of nano-TiO_(2) could significantly enhance the gel strength of HPAM/PEI gel at 80 ℃. The gel strength of the enhanced HPAM/PEI gel with 0.1 wt% nano-TiO_(2) could reach grade I. The system also had excellent high-temperature stability at 150 ℃. The enhanced HPAM/PEI gel with 0.02 wt% nano-TiO_(2) reached the maximum gel strength at 150 ℃ with a storage modulus (G′) of 15 Pa, which can meet the need for efficient plugging. However, the nano-SiO_(2) enhanced HPAM/PEI polymer gel system showed weaker gel strength than that with nano-TiO_(2) at both 80 and 150 ℃ with G′ lower than 5 Pa. Microstructures showed that the nano-TiO_(2) enhanced HPAM/PEI gel had denser three-dimensional (3D) mesh structures, which makes the nano-TiO_(2) enhanced HPAM/PEI gel more firmly bound to water. The FT-IR results also confirmed that the chemical structure of the nano-TiO_(2) enhanced HPAM/PEI gel was more thermally stable than nano-SiO_(2) since there was a large amount of –OH groups on the structure surface. Therefore, nano-TiO_(2) was more suitable as the reinforcing material for HPAM/PEI gels for high-temperature petroleum reservoir conformance improvement.

Research on material design and high-temperature friction and wear properties of new graphitic steel

To solve the problem of the severe mismatch between the product and roll materials in the preliminary rolling line,a new graphitic steel material was designed,its microstructure and high-temperature friction and wear properties were investigated.Moreover,the feasibility of replacing semi-steel with this new material in the V1 stand roll was studied herein.The results show that the graphitic steel matrix is strengthened by silicon and nickel elements.The presence of spherical graphite also provides self-lubrication and heat conduction and prevents the propagation of cracks.Carbides in the appropriate amount and size strengthen the matrix,reduce the cracking effect of the matrix,and are not easily broken,thereby reducing high-temperature abrasive wear.Under the same hightemperature friction and wear conditions,compared with semi-steel,the wear-scar surface of graphitic steel exhibits less wear-scar depth and wear volume,a smaller friction coefficient,reduced oxide layer thickness,and fewer instances of peeling and microcracks.Therefore,the newly designed graphitic steel has higher wear resistance and hot-crack resistance than semi-steel,which makes it feasible for use in replacing semi-steel as a new V1 frame roll material in the blooming mill.

黏结剂喷射制备陶瓷型芯抗弯强度、尺寸精度及表面质量影响因素的研究进展

黏结剂喷射因具有低成本和可控性优势而在陶瓷型芯的制备中得到广泛的应用,但制备陶瓷型芯的抗弯强度、尺寸精度和表面质量一般较低,而这些不足可以通过改变制备工艺参数来进行改进。综述了粉末、黏结剂、成形工艺和后处理工艺这4个方面的参数对陶瓷型芯抗弯强度、尺寸精度和表面质量的影响,提出了提高黏结剂喷射制备陶瓷型芯抗弯强度、尺寸精度和表面质量的未来发展方向。

富集污泥成型低成本粘结剂开发与应用

这是一篇矿业工程领域的论文。针对攀钢富集污泥球团成型粘结剂成本高,粉碎率高等问题,开发出低成本有机粘结剂。并研究了水分、压力、烘干温度等因素对球团落下强度和粉碎率的影响。粘结剂添加1.5%,生球落下强度>5次/m,干球落下强度>28次/2 m,粉碎率<2%,完全满足现场生产要求,吨球粘结剂成本降低35%以上。

CFB飞灰压浆料的制备及高强微膨胀机理研究

利用循环流化床燃煤固硫灰(CFB飞灰)的活性与膨胀性制备压浆料,研究了CFB飞灰掺量和水胶比对压浆料工作性能、强度和膨胀率的影响;CFB飞灰与矿粉以不同比例复配,对比研究了CFB飞灰压浆料的高强微膨胀特性,并采用XRD与SEM分析验证。结果表明,随CFB飞灰替代水泥掺量的增加,压浆料的需水性增强,抗压强度降低,20%(质量分数)CFB飞灰的试样28 d抗压强度与基样接近,可达85.8 MPa,而抗折强度先升高后降低,膨胀率一直升高。随用水量的增加,压浆料的膨胀率降低但均为正值。随CFB飞灰取代矿粉率的提高,压浆料的工作性能降低,28 d抗压强度先升高后降低,其中20%(质量分数)CFB飞灰、10%(质量分数)矿粉复合的试样28 d抗压强度最高,为99.8 MPa,膨胀率一直升高。通过CFB飞灰与矿粉复合配制了各项性能均满足铁标要求的压浆料。CFB飞灰不仅自身水化产生膨胀,还能激活矿粉活性,产生复合增强作用。

自硬-微波加热复合硬化硅酸盐粘结剂砂性能研究

针对自硬硅酸盐粘结剂砂用于铸铁件时存在硬化速度慢、对环境湿度敏感、砂型(芯)强度低、溃散性差四个问题,本文选择一种新型硅酸盐粘结剂,以陶瓷砂为原砂,在采用固化剂自硬的基础上,还通过微波加热以及添加粉末促硬剂,进行了复合硬化工艺的研究。首先,研究了微波加热工艺参数对型砂试样性能的影响,确定了优化微波加热工艺:加热功率为900 W、加热时间为180 s;而后,选用了三种粉末促硬剂进行优化,得到的最佳粉末添加剂优化方案为粘结剂2.2%、微硅粉0.2%、氧化铝0.2%、石英粉0.06%。结果表明,该组优化方案相比较不加入粉末添加剂,使砂型(芯)1 h强度提高至1.86 MPa,24 h强度提高至2.17 MPa,98%RH吸湿强度提高至1.45 MPa,800℃残留强度降低至0.75 MPa,其常温强度值和残留强度值分别达到和接近自硬树脂砂的水平。

Study on the strength of cold-bonded high-phosphorus oolitic hematite-coal composite briquettes

Composite briquettes containing high-phosphorus oolitic hematite and coal were produced with a twin-roller briquette machine using sodium carboxymethyl cellulose, molasses, starch, sodium silicate, and bentonite as binders. The effect of these binders on the strength of the composite briquettes, including cold strength and high-temperature strength, was investigated by drop testing and compression testing. It was found the addition of Ca（OH）2 and Na2CO3 not only improved the reduction of iron oxides and promoted dephosphorization during the reduction-separation process but also provided strength to the composite briquettes during the briquetting process; a compressive strength of 152.8 N per briquette was obtained when no binders were used. On this basis, the addition of molasses, sodium silicate, starch, and ben- tonite improved the cold strength of the composite briquettes, and a maximum compressive strength of 404.6 N per briquette was obtained by using starch. When subjected to a thermal treatment at 1200~C, all of the composite briquettes suffered from a sharp decrease in compressive strength during the initial reduction process. This decrease in strength was related to an increase in porosity of the composite briquettes. X-ray diffraction （XRD） and scanning electron microscopy （SEM） analyses showed that the decrease in strength of the composite briquettes could be caused by four factors： decomposition of bonding materials, gasification of coal, transportation of byproduct gases in the composite briquettes, and thermal stress.

新型硅酸盐自硬粘结剂砂性能的研究

以有机酯为固化剂的普通水玻璃自硬砂具有生产环境好、产生的有害气体少的优势,目前广泛应用于铸钢件的生产。但以硅砂为原砂的水玻璃自硬砂用于生产结构复杂、质量要求高的铸铁件,与树脂砂工艺相比,还存在硬化速度慢,型芯砂强度较低,使用性能对环境湿度敏感等问题。为此,本文以一种新型硅酸盐粘结剂为对象,选用球形陶瓷砂,在固化剂自硬工艺基础上,添加促硬剂和多种粉末改性剂,重点研究了常温强度和高温残留强度的变化规律。正交试验获得的复合粉末改性剂优化配方为:陶瓷砂∶促硬剂∶氧化锆∶氮化硅=1000∶4∶2∶1,粘结剂加入量2.2%,固化剂占粘结剂质量的20%,试样1h强度为0.98MPa,24h强度1.59MPa,800℃残留强度0.62MPa,其常温强度已达到自硬树脂砂的性能指标。

不同类型粘接剂对牙本质粘接强度及耐久性的效果评价

目的:探讨不同类型粘接剂对牙本质粘接强度及耐久性的效果评价。方法:选取2021年6月-2022年6月上海交通大学医学院附属新华医院口腔科就诊的500例患者因治疗需要拔除完整的无龋人离体第三磨牙(共500颗)为研究对象,采用随机数字表法将其分为观察1组(166颗)、观察2组(167颗)和对照组(167颗)。观察1组采用全酸蚀粘接剂,观察2组采用二步法自酸蚀粘接剂,对照组采用一步法自酸蚀粘接剂。统计比较不同类型粘接剂的粘接强度、牙本质微渗漏情况及断裂模式。结果:观察1组、观察2组储存24 h、12个月牙本质微拉伸粘接强度均高于对照组,观察1组、对照组储存12个月牙本质微拉伸粘接强度低于储存24 h(P<0.05);储存24 h、储存12个月时,各组牙本质断裂模式主要为混合断裂,三组不同储存时间牙本质断裂模式相比差异无统计学意义(P>0.05);观察1组、观察2组储存24 h、12个月牙本质微渗漏情况均低于对照组,观察1组、观察2组储存12个月牙本质微渗漏情况低于储存24 h,且观察1组较观察2组低(P<0.05)。结论:全酸蚀粘接剂、二步法自酸蚀粘接剂的粘接强度较好,随着时间推移,二步法自酸蚀粘接剂的粘接强度仍较高,全酸蚀粘接剂的耐久性相对较好,操作过程中临床可根据实际情况选择合适的粘接剂。

Early-age strength property improvement and stability analysis of unclassified tailing paste backfill materials

High-density tailings,small cementitious materials,and additives are used for backfill materials with poor early compressive strength(ECS),which may greatly affect the mining and backfill cycle,to prepare paste backfill materials(PBMs)with a high ECS.The effects and mechanisms of different early strength agents on the property of PBM are investigated.The action mechanism of additives on the properties of PBM is also analyzed through X-ray diffraction,scanning electron microscope,and energy dispersive spectrometry.Results show that the effects of single-component additives 1,3,and 6 are better than those of the other additives,and their optimal dosages are 3wt%,1wt%,and 3wt%,respectively.The optimum multicomponent combinations are 1wt%of additive 1 and 1.5wt%of additive 6.The ECS of the paste with additive 10 increases to a greater extent than that of the other pastes because of the synergistic action of additive 1 with additive 6.The hydration product of Ca(OH)2 is consumed,and more C-S-H gels are generated with the addition of additives to paste.Tailings particles,ettringite crystals,and gels intertwined with one another form a dense net-like structure that fills the pores.This structure can significantly improve the ECS of PBM.