Computational minimization of over-deposition at corners of trajectories in Laser Metal Deposition

Montoya-Zapata, Diego; Creus, Carles; Moreno, Aitor; Ortiz, Igor; Alvarez, Piera; Ruiz-Salguero, Oscar; Posada, Jorge

doi:10.1016/j.mfglet.2021.05.001

Cited by 9 publications

(1 citation statement)

References 15 publications

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“…Other challenges in using LP-DED for IM tooling could include in consistent deposition rates in bends and sharp corners [23], high as-built surface roughness which increase pressure loss [24,25], potential high stress concentrations in smaller channels, and distortion due to thermomechanical stress [26]. These challenges can be addressed by using CCs with alternative non-circular, self-supporting profiles, and by developing effective methods for extending the manufacturability of overhanging features by using the 5-axis control ability of HM to articulate the part during manufacture.…”

Section: Introductionmentioning

confidence: 99%

Hybrid directed energy deposition strategies and manufacturing of tooling with conformal cooling channels

Wilson,

Gupta,

Mazur

et al. 2023

Preprint

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Additive Manufacturing (AM) of Injection Moulding (IM) tools has attracted significant interest in the polymer manufacturing industry for quite some time. However, Hybrid Manufacturing (HM) using Directed Energy Deposition (DED), which involves concurrent additive and subtractive manufacture, has not been a commonly used process for IM tooling manufacture, despite several advantages over the prevalent Laser-Powder Bed Fusion (L-PBF) alternative, including higher build rate, lower cost, and integrated machining to directly achieve higher tolerances and surface finish. A key reason for this low utilisation is the limited ability of DED processes to produce circular channel profiles typically used in IM tooling, due to stricter constraints on the manufacturability of overhanging geometry. To address this, a range of self-supporting IM cooling channel profiles suited for hybrid laser and powder-based DED manufacture are proposed in this work. Numerical and experimental evaluations are conducted of the cooling performance of several non-circular conformal cooling channel (NCCC) profiles to identify a profile which achieves the maximum heat transfer for a constant cross-sectional area and coolant flow rate. Experimental studies included AM builds to evaluate the DED manufacturability of the selected NCCC profile on a conformally cooled HM benchmark model, followed by cooling performance characterisation, including a comparison against a reference L-PBF manufactured benchmark model. In conclusion, a shape correcting factor is obtained using response surfaces. This factor is used to convert thermal performance calculations for non-circular profiles to a conventional circular channel profile to simplify the DED manufacturing process for non-circular IM cooling channels.

show abstract

Section: Introductionmentioning

confidence: 99%

Hybrid directed energy deposition strategies and manufacturing of tooling with conformal cooling channels

Wilson,

Gupta,

Mazur

et al. 2023

Preprint

View full text Add to dashboard Cite

show abstract

Experimental and computational assessment of minimizing overfill in trajectory corners by laser velocity control of laser cladding

Montoya-Zapata

Posada

Alvarez

et al. 2022

Int J Adv Manuf Technol

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Analysis of self-supporting conformal cooling channels additively manufactured by hybrid directed energy deposition for IM tooling

Wilson,

Gupta,

Mazur

et al. 2024

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Additive manufacturing (AM) of injection moulding (IM) tools has attracted significant interest in the polymer manufacturing industry for quite some time. However, hybrid manufacturing (HM) using directed energy deposition (DED), which involves concurrent additive and subtractive manufacture, has not been a commonly used process for IM tooling manufacture. This is apparent despite several advantages over the prevalent laser-powder bed fusion (L-PBF) alternative, including higher build rate, lower cost and integrated machining to directly achieve higher tolerances and surface finish. A key reason for this low utilisation is the limited ability of DED processes to produce circular channel profiles typically used in IM tooling, due to stricter constraints on the manufacturability of overhanging geometry. To address this, a range of self-supporting IM cooling channel profiles suited for hybrid laser and powder-based DED manufacture are proposed in this work. Numerical and experimental evaluations are conducted of the cooling performance of several non-circular conformal cooling channel (NCCC) profiles to identify a profile which achieves the maximum heat transfer for a constant cross-sectional area and coolant flow rate. Experimental studies included AM builds to evaluate the DED manufacturability of the selected NCCC profile on a conformally cooled HM benchmark model, followed by cooling performance characterisation, including a comparison against a reference L-PBF manufactured benchmark model. In conclusion, a shape correcting factor is obtained using response surfaces. This factor is used to convert thermal performance calculations for non-circular profiles to a conventional circular channel profile to simplify the DED manufacturing process for non-circular IM cooling channels.

show abstract

Computational minimization of over-deposition at corners of trajectories in Laser Metal Deposition

Cited by 9 publications

References 15 publications

Hybrid directed energy deposition strategies and manufacturing of tooling with conformal cooling channels

Hybrid directed energy deposition strategies and manufacturing of tooling with conformal cooling channels

Experimental and computational assessment of minimizing overfill in trajectory corners by laser velocity control of laser cladding

Analysis of self-supporting conformal cooling channels additively manufactured by hybrid directed energy deposition for IM tooling

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