Prototyping and modeling of the centrifugal casting process for paraffin waxes

Centrifugal casting is a technology used for manufacturing hybrid rocket paraffin grains. This technology helps avoiding voids formation inside the solid paraffin as it cools. Voids are formed because of air bubbles being entrapped while pouring and because the liquid wax shrinks by 17–19% upon cooling. In this work, the centrifugal casting process for the manufacturing of paraffin cylinders was prototyped at two different scales considering critical casting issues. The effects of process parameters (rotational speed, melt temperature, and flow rate) on the tensile properties of the manufactured grains were analyzed. The results of the optimization conducted at the lower scale (2.5 kg) were up scaled to manufacture 25 kg grains. The resulting mechanical properties complied with the design specifications, and they were better than those characterized from the gravity cast wax. A numerical model of growth and dissolution of bubbles during the process was then developed to predict the quality of the castings. The numerical results showed how increasing the mold rotational speed up to 1800 rpm reduced the removal time. However, compared to grains solidification time, the predicted removal times were much shorter, proving the advantage of centrifugal casting in counteracting voids formation.