Optimization of Process Parameters for Additively Produced Tool Steel 1.2709 with a Layer Thickness of 100 μm

Andronov, V. N.; Šimota, Jan; Beránek, Libor; Blažek, Jiří; Rušar, Filip

doi:10.3390/ma14112852

Cited by 8 publications

(3 citation statements)

References 27 publications

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“…Direct confirmation of this theory by measuring the meltpool width on metallographic samples was not reliable due to the overlap. For this purpose, it would be necessary to create and evaluate single laser track samples as published in [49,50].…”

Section: Notch Impact Toughnessmentioning

confidence: 99%

Mechanical and Microstructural Anisotropy of Laser Powder Bed Fusion 316L Stainless Steel

et al. 2022

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This paper aims at an in-depth and comprehensive analysis of mechanical and microstructural properties of AISI 316L austenitic stainless steel (W. Nr. 1.4404, CL20ES) produced by laser powder bed fusion (LPBF) additive manufacturing (AM) technology. The experiment in its first part includes an extensive study of the anisotropy of mechanical and microstructural properties in relation to the built orientation and the direction of loading, which showed significant differences in tensile properties among samples. The second part of the experiment is devoted to the influence of the process parameter focus level (FL) on mechanical properties, where a 48% increase in notched toughness was recorded when the level of laser focus was identical to the level of melting. The FL parameter is not normally considered a process parameter; however, it can be intentionally changed in the service settings of the machine or by incorrect machine repair and maintenance. Evaluation of mechanical and microstructural properties was performed using the tensile test, Charpy impact test, Brinell hardness measurement, microhardness matrix measurement, porosity analysis, scanning electron microscopy (SEM), and optical microscopy. Across the whole spectrum of samples, performed analysis confirmed the high quality of LPBF additive manufactured material, which can be compared with conventionally produced material. A very low level of porosity in the range of 0.036 to 0.103% was found. Microstructural investigation of solution annealed (1070 °C) tensile test samples showed an outstanding tendency to recrystallization, grain polygonization, annealing twins formation, and even distribution of carbides in solid solution.

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Section: Notch Impact Toughnessmentioning

confidence: 99%

Mechanical and Microstructural Anisotropy of Laser Powder Bed Fusion 316L Stainless Steel

et al. 2022

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“… 36 The behavior of the material and the optimization of the parameters for every material are necessary, which the authors examined and verified in the study. 37 Therefore, AUDI AG has developed its parameters with 37% reduced printing time than the standard parameter. Applicators can choose between different standard exposure patterns.…”

Section: Methodsmentioning

confidence: 99%

Case Study of Large Three-Dimensional-Printed Slider with Conformal Cooling for High-Pressure Die Casting

Andronov

Beránek

Šotka

et al. 2023

3D Printing and Additive Manufacturing

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Metal three-dimensional (3D) printing technology brings several benefits to the field of high-pressure die casting of aluminum, which enhances its development. The associated conformal cooling application is already commonly used where there is a need to improve the quality of castings, increase tool life, or reduce the production cycle. However, will this technology withstand the production of a large part (∼270 × 270 × 200 mm), which will be used directly in the serial production of engine blocks? This article describes a slider with a conformal cooling case study, which was redesigned and manufactured using the laser powder bed fusion (L-PBF) method. After the slider was put into serial production of 1.0 TSI three-cylinder engine blocks, this tool was thoroughly monitored based on the temperature field by comparing the results of a simulation in SW ProCAST with reality, and furthermore examining the influence of the tool on the quality of castings. There was also an evaluation of repairs performed on the tool in the ŠKODA AUTO tool shop and the foundry. These data were compared with a serial tool. Finally, the costs to produce the slider in conventional and 3D-printed variants are compared with an outline of other possible steps for optimizing these costs. The study results show that relatively large parts can be printed and used in serial production even today. It was also confirmed that conformal cooling influenced improving tool life, and the number of repairs in ŠKODA AUTO production also decreased.

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“…The laser energy in LPBF could also engender patterns on the surface of materials which affect their properties such as tribology and biocompatibility [8]. Researchers around the globe have successfully endeavoured to optimize the process parameters of LPBF for fabricating different materials such as titanium-based alloys, steel alloys, and aluminium-based alloys [9][10][11]. In fact, Electro Optical Systems (EOS) offers a range of validated processes parameters for steel, titanium-based, and aluminium-based alloys that are optimal in order to ensure that the properties of the additively manufactured parts are consistently achieved with minimal defects [12].…”

Section: Introductionmentioning

confidence: 99%

Effects of Quasi-Static Strain Rate and Temperature on the Microstructural Features of Post-Processed Microstructures of Laser Powder Bed Fusion Ti6Al4V Alloy

Muiruri,

Maringa,

du Preez

2024

Applied Sciences

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This study documents an investigation of the flow stress properties and microstructural features of Ti6Al4V (ELI) alloy produced using laser powder bed fusion (LPBF). Selected heat treatment strategies were applied to the material to obtain different microstructures. The influence of quasi-static strain rates and temperature on the obtained microstructures of this material and their strain hardening properties are documented in this study. All microstructures of the alloy formed in this study were found to be sensitive to quasi-static strain rates and temperatures, where their flow stresses increased with increasing strain rate and decreased for tests conducted at elevated temperatures. The strain hardening rates of the fine microstructures were found to be high compared to those of coarse microstructures. The strain hardening rates for the various forms of LPBF Ti6Al4V (ELI) examined here were found to diminish with increasing test temperature. Though the deformed surfaces of the built samples were largely dominated by adiabatic shear bands (ASBs), the absence of ASBs was noted for all samples tested at a temperature of 500 °C and an imposed strain of 30%.

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Optimization of Process Parameters for Additively Produced Tool Steel 1.2709 with a Layer Thickness of 100 μm

Cited by 8 publications

References 27 publications

Mechanical and Microstructural Anisotropy of Laser Powder Bed Fusion 316L Stainless Steel

Mechanical and Microstructural Anisotropy of Laser Powder Bed Fusion 316L Stainless Steel

Case Study of Large Three-Dimensional-Printed Slider with Conformal Cooling for High-Pressure Die Casting

Effects of Quasi-Static Strain Rate and Temperature on the Microstructural Features of Post-Processed Microstructures of Laser Powder Bed Fusion Ti6Al4V Alloy

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