Synopsis
This study presents an innovative solution to address wear, adhesion, and dimensional accuracy problems encountered in sand core molds used in low-pressure aluminum casting and gravity die
casting processes. In conventional steel sand core molds, wear occurring during the filling of sand into the mold surface shortens mold life, reduces production efficiency, and leads to dimensional
deviations. Existing maintenance and repair methods fail to permanently eliminate these issues, thereby negatively affecting production continuity.
In this study, the use of specially designed polytetrafluoroethylene (PTFE, Teflon) components is proposed for the critical regions of steel sand core molds that are exposed to wear. By integrating
PTFE materials into mold surfaces, friction and adhesion effects occurring during sand flow are significantly reduced, thereby minimizing surface deformation. This approach ensures the preservation of dimensional accuracy in sand core production while improving production repeatability and process stability.
The investigated PTFE components are strategically positioned at contact surfaces exposed to high abrasive effects, particularly during the sand injection process. As a result, mold life is extended, maintenance requirements and production downtime are reduced, and overall production quality is sustainably improved.
This study not only introduces an alternative material application but also presents a functional improvement approach integrated into mold design. In this respect, it offers a comprehensive solution that directly enhances mold performance, production efficiency, and process reliability.
In conclusion, the developed PTFE-supported sand core mold system is considered an innovative approach that contributes to cost reduction, quality consistency, and sustainable manufacturing goals in the casting industry.
