Ecological and Economic Benefits of Additive Manufacturing in High Pressure Die Casting

Wiedenegger, Armin; Bruckwilder, Johannes; Deutsch, C.

doi:10.1007/s00501-021-01110-5

Cited by 7 publications

(2 citation statements)

References 3 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Additive processing of 18Ni maraging steels is also of avid interest for architecting conformal channels [5,6] for transpiration cooling, so as to mitigate partial reversion of martensite into austenite [7], as well as the accompanying strength losses and geometric instabilities [5,[8][9][10][11], especially during cyclic/extended service at elevated temperatures. To date, this improved cooling efficiency-which was made possible in maraging steel parts designed with novel conformal channels and fabricated using metal AM technologies (particularly with LPBF processing)-has reduced process cycle times in injection molding [12] of plastics and, more recently, in high-pressure die casting of metals [13], where the pressures and temperatures are significantly greater.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of Maraging Steel Produced Using Hybrid Additive/Subtractive Manufacturing

Sarafan

Wanjara

Gholipour

et al. 2021

JMMP

View full text Add to dashboard Cite

Hybrid manufacturing is often used to describe a combination of additive and subtractive processes in the same build envelope. In this research study, hybrid manufacturing of 18Ni-300 maraging steel was investigated using a Matsuura LUMEX Avance-25 system that integrates metal additive manufacturing using laser powder bed fusion (LPBF) processing with high-speed machining. A series of benchmarking coupons were additively printed at four different power levels (160 W, 240 W, 320 W, 380 W) and with the integration of sequential machining passes after every 10 deposited layers, as well as final finishing of selected surfaces. Using non-contact three-dimensional laser scanning, inspection of the final geometry of the 18Ni-300 maraging steel coupons against the computer-aided design (CAD) model indicated the good capability of the Matsuura LUMEX Avance-25 system for net-shape manufacturing. Linear and areal roughness measurements of the surfaces showed average Ra/Sa values of 8.02–14.64 µm for the as-printed walls versus 0.32–0.80 µm for the machined walls/faces. Using Archimedes and helium (He) gas pycnometry methods, the part density was measured to be lowest for coupons produced at 160 W (relative density of 93.3–98.5%) relative to those at high power levels of 240 W to 380 W (relative density of 99.0–99.8%). This finding agreed well with the results of the porosity size distribution determined through X-ray micro-computed tomography (µCT). Evaluation of the static tensile properties indicated that the coupons manufactured at the lowest power of 160 W were ~30% lower in strength, 24% lower in stiffness, and more than 80% lower in ductility relative to higher power conditions (240 W to 380 W) due to the lower density at 160 W.

show abstract

Section: Introductionmentioning

confidence: 99%

Evaluation of Maraging Steel Produced Using Hybrid Additive/Subtractive Manufacturing

Sarafan

Wanjara

Gholipour

et al. 2021

JMMP

View full text Add to dashboard Cite

show abstract

“…It is preferably employed in the die and tooling industry as well as in structural and aerospace applications [55,56]. The use of maraging steel in PBF-LB/M is also stimulated by the poten-tial of generating cooling channels for the reduction of cycle times in injection moulding [57] of plastics and high-pressure casting of metals [58].…”

Section: Specimen Design and Materialsmentioning

confidence: 99%

Static and Dynamic Mechanical Behaviour of Hybrid-PBF-LB/M-Built and Hot Isostatic Pressed Lattice Structures

2023

View full text Add to dashboard Cite

We report on a comprehensive study of the mechanical properties of maraging steel body-centred cubic lattice structures fabricated by a hybrid additive manufacturing technology that combines laser powder bed fusion with in situ high-speed milling. As the mechanical properties of additive manufactured components are inferior to, e.g., cast components, surface modifications can improve the mechanical behaviour. Different hybrid additive manufacturing technologies have been designed using additive and subtractive processes, improving process quality. Following this, mechanical testing is performed with respect to static tensile properties and dynamic stress, hardness, and porosity, comparing specimens manufactured by laser powder bed fusion only to those manufactured by the hybrid approach. In addition, the influence of different heat-treatment techniques on the mechanical behaviour of the lattice structures is investigated, namely solution and aging treatment as well as hot isostatic pressing. Thus, the influence of the superior surface quality due to the hybrid approach is evaluated, leading to, e.g., an offset of about 14–16% for the static testing of HIP lattice structures. Furthermore, the dynamic load behaviour can be improved with a finished surface, heading to a shift of the different zones of fatigue behaviour in the testing of hybrid-built specimens.

show abstract

Integration of Additive Fabrication with High-Pressure Die Casting for Quality Structural Castings of Aluminium Alloys; Optimising Energy Consumption

Anand

Nagarajan

Mansori

et al. 2022

Trans Indian Inst Met

View full text Add to dashboard Cite

Ecological and Economic Benefits of Additive Manufacturing in High Pressure Die Casting

Cited by 7 publications

References 3 publications

Evaluation of Maraging Steel Produced Using Hybrid Additive/Subtractive Manufacturing

Evaluation of Maraging Steel Produced Using Hybrid Additive/Subtractive Manufacturing

Static and Dynamic Mechanical Behaviour of Hybrid-PBF-LB/M-Built and Hot Isostatic Pressed Lattice Structures

Integration of Additive Fabrication with High-Pressure Die Casting for Quality Structural Castings of Aluminium Alloys; Optimising Energy Consumption

Contact Info

Product

Resources

About