Este trabalho tem como foco central a investigação de possibilidades de obtenção de peças metálicas, na forma de esculturas, por fundição, com vazamento por gravidade e que tenham como característica formal uma geometria complexa. Na interface interdisciplinar entre Arte e Engenharia, o estudo aborda a técnica de fundição por cera perdida e suas características, os materiais envolvidos nos processos de construção do modelo e do molde, e a realização prática de peças fundidas. Através do fazer, da aplicação das técnicas de fundição, da construção de um relato de experiências e das reflexões geradas a partir da análise dos resultados, o texto procura estabelecer a viabilidade da aplicação das técnicas de fundição por cera perdida, em atelier de escultura, com propósitos artísticos. / The following work has as its central focus the investigation of possibilities in the attainment of metallic pieces, in the form of sculptures, through foundry with filling by gravity and a complex geometry as their formal characteristic. In the interdisciplinary interface between Art and Engineering, the study approaches the lost wax foundry technique and its characteristics, as well as the materials involved in the processes of construction of the model and the mold and the practical accomplishment of the foundry pieces. The text attempts to establish the viability of the employment of the foundry techniques of lost wax through the execution, the application of the foundry techniques, the elaboration of a report of experiences and the thoughts generated from the analysis of the results in a sculpture studio with artistic purposes.

Les méthodologies de conception des grappes de fonderie reposent fondamentalement sur l’analyse de l’énergie dégagée par le métal au cours de sa solidification. En effet, l’interprétation de ces transferts thermiques permet de calculer localement le temps de solidification et donc d’identifier les points chauds d’une pièce de fonderie. Dans le cas du moulage en sable, ces échanges thermiques sont bien connus et depuis longtemps modélisés (Chvorinov). Leur modélisation correspond à un moule thermiquement infini, c’est à dire que toute l’énergie dégagée par le métal lors de sa solidification est absorbée par le moule. En revanche, dans le cas d’une carapace ou d’une coquille, une partie de cette énergie est transmise à l’environnement via le moule ; ainsi la modélisation la plus adaptée sera donc celle considérant le moule comme un milieu thermiquement fini. Des manipulations de référence ont permis d’acquérir une bonne compréhension des mécanismes thermiques intervenant dans ce procédé de fonderie et mettent en évidence toute la complexité des échanges, à la fois internes et externes au moule (qui se produisent en simultané pendant la phase de solidification du métal). Ces manipulations ont permis par ailleurs, à l’aide de modèles statistiques, d’estimer les paramètres physiques qui sont difficilement accessibles du fait de leurs dépendances et des conditions de travail expérimentales (les échanges avec le milieu ambiant, le coefficient d’échange et le flux entre le métal et le moule). Ces valeurs issues d'expérimentations réalisées en condition réelles serviront à alimenter les bases de données matériaux utilisées en fonderie et dans les simulations numériques. La démarche et les modèles développés dans le cadre de ce travail de thèse permettent un calcul plus fiable qui servira au dimensionnement des masselottes dans le cas du procédé à cire perdue. A plus long terme, cette démarche pourrait être étendue à d’autres procédés de fonderie puisque la méthodologie développée sur du moulage à cire perdue sera transposable aux cas des moules à noyau, des moules métalliques ou autres procédés similaires. / Design casting methodologies are based on the analysis of the energy released by the metal during its solidification. Indeed, the knowledge of this heat transfer permits to faithfully predict local solidification time and to identify last solidified zones. In the case of sand casting, heat exchanges are well known and have been modeled for a long time (Chvorinov). The last, modelize "thermally infinite mold" so in this case whole metal energy threw solidification phase is absorbed by the mold. In contrary, for a shell, a portion of metal energy is transmitted to environment threw the shell, so in this case, the most appropriate model is "a thermally finished mold". Reference experimentations gives a good understanding of energy / thermal mechanisms involved in the casting process and highlight both internal and external shell thermal exchanges complexity (which occur simultaneously during solidification metal). These manipulations allow to use inverse method to estimate hardly measured parameters (such as external heat transfer coefficient or metal-mold interfacial heat transfer), and therefore to build reliable thermal parameters databases used in numerical simulations. Methodology and models developed in this study allow a reliable sizing feed calculation for investment casting. On the long-range, this knowledge could be applied to other foundry processes since the methodology developed on investment casting will be transposed to core molds, die-casting or other molds.

Conventional urea-based moulding compounds for investment casting patterns are manufactured using a slow “cooking” process. Nowadays in industrial processes the use of a faster process is highly recommended to increase throughput levels. At the same time, for quality control purposes, the requirements of an investment caster must be met. This study is therefore focused on: <ul><li> Finding the appropriate conventional process and conditions to prepare urea-based investment casting moulding compounds. </li><li> Optimising the composition variables to meet the mechanical, thermal, surface, flow and cost properties needed in investment casting. </li><li> Characterising the moulding compounds to meet the requirements of an investment caster by comparing them with an industrial, “cooked” urea-based compound. </li></ul> Polyvinyl alcohol (PVOH) and ethylene vinyl acetate (EVA) urea-based moulding compounds were prepared using a two-roll mill and a conventional extrusion processes respectively. It was possible to injection mould PVOH urea-based moulding compounds with a urea content of up to 90 wt % which had been compounded using a two-roll mill. Using the conventional extrusion process, it was also possible to compound and injection mould EVA urea-based moulding compounds containing up to 70 wt % urea. The effects on composition variables on the properties of the moulding compound were studied and compared to those of the existing “cooked” urea-based moulding compound (Benchmark). The mechanical properties were characterised using the three-point bending test and Charpy impact test. The thermal properties were determined using simultaneous differential thermal analysis and thermogravimetric analysis (SDTA/TGA) and differential scanning calorimeter (DSC). The thermo-mechanical and visco-elastic properties were determined using a dynamic mechanical analyser. A scanning electron microscope was used to study the surface texture of the mouldings. The EVA urea-based moulding compounds showed two endothermic melting peaks and multiple exothermic crystallisation peaks in the DSC curves. The peak at ca. 55 - 66°C corresponds to the melting of the wax/EVA blend, while the large peak at 130 - 132°C corresponds to the melting of the urea. The DSC heating curve of the PVOH urea-based moulding compounds showed two endothermic peaks. The small peak corresponds to the melting of the wax, while the large peak corresponds to the melting of the urea/PVOH blend. PVOH urea-based moulding compound had better mechanical properties than the industrial benchmark. The mechanical properties of the EVA urea-based compound were generally lower. The effect of the wax and polymer content on the mechanical properties was as follows: <ul><li> Increasing polymer content produced weaker but tougher moulding compounds. </li><li> Increasing wax content improved the strength and stiffness but gave compounds that were less tough. </li><li> Two-way Analysis of Variance (ANOVA) indicated significant polymer-wax interactions. </li></ul> The urea content determined the stiffness (elastic modulus) of the compounds. PVOH mouldings had superior stiffness compared with the EVA and cooked urea-based mouldings. The Dynamic mechanical analysis (DMA) results confirmed the result obtained from the modulus of elasticity determination in the three-point bending test. The impact strength increased with an increase in polymer content and reduced with an increase in wax content. The linear thermal expansion coefficient decreased as the urea content was increased. Measured values (100 to 156x10-6°C) were comparable to those of the benchmark. The cooked urea-based moulding compound had the lowest melt viscosity at 110°C, as indicated by its melt flow index (MFI). Fluidity increased with the polymer content. The thermo gravimetric analysis (TGA) results confirmed that both the PVOH and EVA urea-based moulding compounds decomposed readily and left less than 1 wt % ash after combustion. From the SEM results apparent surface roughness appeared to increase with wax content. The EVA urea-based moulding compound had an irregular surface texture. Based on the criteria of cost-effectiveness and environmental friendliness, the synthesis of PVOH urea-based patterns is preferable. The use of a conventional extrusion process to prepare PVOH urea-based patterns is recommended. / Thesis (PhD)--University of Pretoria, 2011. / Chemical Engineering / unrestricted

The diploma thesis deals with the possibilities of using numerical simulation in investment casting technology. The first chapter of practical part deals with the use of simulations in the design of gating system for the shape-complex casting. At the same time, the practical part verified the accuracy of the simulation by test castings on which the X- ray inspection was performed. The results showed that the occurrence of internal defects predicted by simulation corresponded to the locations in the test casts. Next part of the thesis describes improvement of the use of liquid metal (so called “yield”) by numerical simulations. Two specific castings were chosen to perform simulation of current and newly designed variant of the gating system.

Diploma thesis contains introduction into shell drying, its monitoring and influence on shell properties. The thesis works with the Cyclone machine described further. The shell drying process in the machine and experiments are carried out broadening understanding of functions and parameters of rapid drying process. Experiments comparing courses of drying under respective settings of Cyclone and under common drying in air-conditioned room are carried out. Also mechanical properties of commonly dried shells and shells made by the Cyclone machines are compared. The positive effect of the machine on the ultimate strenght of dried shells and positive effect on the drying speed has been confirmed.

The diploma thesis deals with the design and production of an aluminum injection mold for investment casting. The work briefly describes the technology of investment casting together with a description of the types of molds, their internal arrangement and the most commonly used materials. Another part of the work is devoted to the analysis of aluminum molds machining. Emphasis was placed mainly on those operations, that will be used in production of mold. The practical part describes in detail the process of designing the model and mold, as well as the process of designing production technology. The construction is performed using the program SolidWorks, production technology using the program SolidCam. At the end of the work, the mold is assembled and the functionality of the mold is verified by means of test injection and economic evaluation is made.

Determining accuracy of wax patterns is an important in wide implementing rapid prototyping methods in investment casting. This experiment is comparing wax pattern accuracy produced in classical metal die and silicone mould. It has been found out, that wax patterns produced by the silicone mould are ounly about one or two accuracy steps worse then wax patterns produced by classical metal die.

The aim of my diploma thesis was to find the possibilities of reaching the dimensional tolerance in the individual phases of casting by the investment casting process. The accuracy of the selected wax patterns and castings were measured by a caliper. At first the selected dimensions of the wax models were measured right after taking them out of the mold and then they were measured during seven days. The castings were measured after pouring. The obtained figures were statistically evaluated. The results show that the large-scale and thick-wall wax model should be coated after seven days of stabilization because the dimensions of the wax model are not stable.

The goal of the diploma thesis is to verify the possibilities of obtaining the casting of the femur component of the customized knee replacement using the technology of Rapid Prototyping and investment casting. To get the wax pattern it is used the method of fabrication the silicon rubber mould. Its optimalization from the wax pattern quality, economy of production and cooling speed aspects is important parameter at repeated production of the wax patterns.

This diploma theses deals with possibilities of using numerical simulation for optimizing production of highly demanding thin-section casting produced by investment casting process. The casting made of aluminium alloy in which the manufacturing process was very problematic (occurrence of macro and micro shrinkages) has been chosen. By numerical simulation the existing technology has been analysed and based on this the possible reasons for defects found. This was later confirmed also by metallographic examinations. Following to this several options for a new technology were proposed and again by simulation checked their suitability. By comparing all above mentioned options two versions have been chosen in the end which was later tested in production with satisfactory results.