Multiscale Analysis of Surface Topography for Engineering Applications in the Casting Industry

Area of Science:

• Materials Science and Engineering
• Manufacturing Technology

Background:

• Casting models are crucial for producing high-quality castings.
• Additive manufacturing technologies are increasingly adopted in various industries.
• Understanding the impact of manufacturing processes on surface topography is essential for quality control.

Purpose of the Study:

• To assess the influence of the molding process on the surface irregularity variability of casting models.
• To compare the surface topography characteristics of models produced by traditional machining and additive manufacturing.
• To evaluate the applicability of additive technologies in relation to surface topography changes.

Main Methods:

• Utilized a multiscale method, specifically wavelet transformation (discrete and continuous), for surface irregularity analysis.
• Manufactured test samples using traditional methods (machining of aluminum and wood) and three additive technologies.
• Employed Analysis of Variance (ANOVA) for statistical assessment of surface differences before and after forming cycles.

Main Results:

• The molding process has a relatively small impact on surface topography, primarily affecting long-term irregularity components.
• Statistical analysis confirmed the ability to distinguish surfaces before and after forming cycles.
• No significant functional dependencies were found between the forming process's impact on surface topography variation and the manufacturing method or its parameters.

Conclusions:

• Additive manufacturing technologies show potential for producing casting models with acceptable surface topography.
• The molding process's effect on surface irregularities is minimal and predictable.
• Further research can explore optimizing additive processes for enhanced surface finish in casting applications.