We have investigated two methods to make cores; using a pourable ceramic and using 3-D powder printing. The pourable ceramic material develops very little heat when mixed with water and can be poured directly on a wax pattern with no distortion. We have used it with Al and ferrous alloys. We have developed a ceramic powder and liquid binder that can be used to print complicated cores directly from a computer generated design with commercially available 3-D powder printers. These cores can be used in place of soluble and injection molded cores. To date, the 3-D cores have been used with Al castings. Both types of cores give good surface finish, have excellent dimensional tolerances, and are a seamless fit with existing shell building, pattern removal, and the other down-stream casting processes.
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