Determination of mechanical characteristics of sand core with inorganic binder through a correlation method between experimental tests and numerical simulations

This study is inserted in the engineering consultancy activity of DACA-I Powertrain Engineering and in particular it is part of a project ICARO that the company developed in collaboration with the metallurgical plant of Teksid SpA located in Carmagnola (To). The thesis work deals with the definition of mechanical characteristics of sand cores with inorganic binder used in gravitational die casting with aluminum alloy and permanent steel mold. Attention towards inorganic binders is growing up due to a lower hazardous gas generation and safer working condition during the casting process. An initial experimental activity is carried out, it consists in a series of high temperature 3-point bending tests on bar specimens made of agglomerate material, special foundry sand linked with inorganic binder. A statistical approach is used to define the mechanical characteristics, exploiting the Weibull distribution function. The following part of the work consists in the realization of simulation activities to characterize material properties and in particular the interaction behavior of sand core with molten metal.