Determination of optimum process and design parameters for cylinder blocks castings produced with 3d printed cores

3D (3 dimensional) printers have started to be used in the casting industry, as in many other sectors. This technology is especially used in the production of cores in the foundry industry. 3D printers enable cores with very complex geometry to be produced without a core box. In this thesis, simulation studies were carried out to determine the optimum process and design parameters in engine block casting with cores produced on a 3D printer. Design studies of cores have been done in computer-aided 3D design programs. The cores produced in 3D printers were assembled and the engine blocks were cast with the optimum process parameters determined in the simulation studies. Simultaneously, the engine block was cast into the green sand mold, which is the traditional casting method. These engine blocks poured into the cores and the engine blocks poured with the traditional method were compared in detail in this study. Microstructure, tensile test, notch impact test, hardness samples were taken from different parts of the engine blocks. In microstructure investigations, graphite structures and perlite ratios were investigated. Breaking strength, notch impact energy and hardness results were evaluated in mechanical tests. In the light of the findings, the engine blocks produced in both molds have a 99% pearlitic structure. The breaking strength and hardness values of the samples taken from the engine blocks poured into the resin sand mold are higher than the samples taken from the engine blocks produced in the green sand mold. The impact energy of the samples taken from the engine blocks produced in the green sand mold is higher than the impact energy of the samples taken from the engine blocks produced in the resin sand mold. In the X-ray examinations, the internal strength of the engine blocks produced in both different mold types was evaluated and no casting defect was found in either of them.