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<p>This study validates the fabrication of overhead catenary components for a 350&#xa0;km/h electric railway using a casting process with 3D-printed sand molds. The research aimed to confirm binder jetting 3D printing as a rapid alternative to conventional casting. The three components manufactured according to Korea Railroad Safety Authority Standards (KRSA) were a clevis-end terminal clamp from CuAl10Fe<sub>2</sub>, a torsion double clevis from GCD450-10, and a suspension clamp from AC3A. The process involved creating sand molds from 3D CAD models via a binder jetting printer, with casting simulations performed to optimize mold design. The resulting prototypes were subjected to a comprehensive quality assessment, including chemical composition analysis, mechanical property tests, non-destructive testing, and dimensional verification. The results confirmed that all components met the chemical and mechanical requirements of KRSA standards. The GCD450-10 torsion double clevis notably exhibited a graphite spheroidization rate of 82%, indicating casting quality equivalent to traditional methods. All prototypes passed non-destructive tests and satisfied dimensional tolerances. This study concludes that manufacturing with 3D-printed sand molds is an effective method for producing high-quality catenary components, significantly reducing production time while ensuring the performance and reliability required for high-speed railway electrification.</p>

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Manufacturing and Performance Evaluation of Overhead Catenary Components Using 3D-Printed Sand Molds

  • 期刊论文

  • 发表日期：

    2025年10月14日

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  • Wan-Shik Oh,
  • Won-Il Shin,
  • Tae-Hyun Kim,
  • Hunseo Lee,
  • Young Park

摘要

This study validates the fabrication of overhead catenary components for a 350 km/h electric railway using a casting process with 3D-printed sand molds. The research aimed to confirm binder jetting 3D printing as a rapid alternative to conventional casting. The three components manufactured according to Korea Railroad Safety Authority Standards (KRSA) were a clevis-end terminal clamp from CuAl10Fe2, a torsion double clevis from GCD450-10, and a suspension clamp from AC3A. The process involved creating sand molds from 3D CAD models via a binder jetting printer, with casting simulations performed to optimize mold design. The resulting prototypes were subjected to a comprehensive quality assessment, including chemical composition analysis, mechanical property tests, non-destructive testing, and dimensional verification. The results confirmed that all components met the chemical and mechanical requirements of KRSA standards. The GCD450-10 torsion double clevis notably exhibited a graphite spheroidization rate of 82%, indicating casting quality equivalent to traditional methods. All prototypes passed non-destructive tests and satisfied dimensional tolerances. This study concludes that manufacturing with 3D-printed sand molds is an effective method for producing high-quality catenary components, significantly reducing production time while ensuring the performance and reliability required for high-speed railway electrification.