Hybrid layered manufacturing of a bimetallic injection mold of P20 tool steel and mild steel with conformal cooling channels

Kapil, Sajan; Legesse, Fisseha; Negi, Seema; Karunakaran, K. P.; Bag, Swarup

doi:10.1007/s40964-020-00129-3

Cited by 16 publications

(4 citation statements)

References 29 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The changes lead to a gradual transformation of the material properties and functions. In particular, Kapil et al [ 33 ] showed that bimetallic objects manufactured by a rapid tooling process reduced the manufacturing cycle time, improved the part integrity, and reduced the overall production cost through the use of cheaper materials. Shang et al [ 34 ] analyzed FGMs based on TA15 and Inconel 718 alloys, particularly the peculiarities of crack formation, microstructure, and mechanical properties.…”

Section: Resultsmentioning

confidence: 99%

On the Features of Composite Coating, Based on Nickel Alloy and Aluminum–Iron Bronze, Processed by Direct Metal Deposition

et al. 2021

View full text Add to dashboard Cite

In recent years, additive manufacturing technologies have become increasingly widespread with the most intensive development being direct metal deposition (DMD), alloys, and ceramic materials on a metal substrate. This study shows the possibilities of the effective formation of coatings, based on heterogeneous metal alloys (Ni-based alloy and Fe-Al bronze) deposited onto 1045 structural steel. Changes in the microhardness, the microstructure, and the tribological properties of the composite coating, depending on the laser spot speed and pitch during DMD processing, have been considered. It was revealed that if the components of the composite coating are chosen correctly, there are possible DMD conditions ensuring reliable and durable connection between them and with the substrate.

show abstract

Section: Resultsmentioning

confidence: 99%

On the Features of Composite Coating, Based on Nickel Alloy and Aluminum–Iron Bronze, Processed by Direct Metal Deposition

et al. 2021

View full text Add to dashboard Cite

show abstract

“…If two or more of these strategies are used to realize a component, it will be called a hybrid-layering strategy. Typically, parts fabricated by WAAM are horizontal deposition with uniformed layer thickness (Cunningham et al, 2018) (Kapil et al, 2020). However, using multi-axis kinematics for the motion has given scope for conformal deposition by WAAM.…”

Section: Hybrid-layering Strategiesmentioning

confidence: 99%

Hybridization in wire arc additive manufacturing

2022

Self Cite

View full text Add to dashboard Cite

Wire Arc Additive Manufacturing (WAAM) can produce a near-net shape of an object within a short period due to its capability of high deposition rate compared with other metal Additive Manufacturing (AM) processes. The recent developments in the WAAM have increased its efficiency and cost-effectiveness in producing viable products. However, poor surface quality, porosities, residual stresses, distortions, and anisotropic mechanical properties are a few inherent challenges still associated with the WAAM, which necessitates the hybridization of this process. Hybrid-WAAM is a synergic integration of one or more deposition processes, manufacturing processes, layering strategies, raw stock materials, and machine tool kinematics that are fully coupled and affect part quality, functionality, and process performance. This paper comprehensively reviews different levels of hybridization in the WAAM to eliminate its associated challenges. These levels of hybridizations are classified into five categories: hybrid-deposition processes, hybrid-manufacturing processes, hybrid-layering strategies, hybrid-machine tools, and hybrid-raw stock. Furthermore, these levels of hybridization are mapped to eliminate the associated defects/challenges in the WAAM, which will help the readers select an appropriate level of hybridization.

show abstract

“…By incorporating highly conductive materials such as copper, the mold performance can be increased as much as 70% [17,18]. Recent studies by Kapil et al and Pragana et al have shown that conformal cooling channels can be produced with wire-arc DED [19,20]. Furthermore, DED enables the manufacturing of complex shapes that are impossible using traditional manufacturing techniques, such as machining, and at a size scale not seen with other additive manufacturing techniques, such as LPBF.…”

Section: Introductionmentioning

confidence: 99%

Hybrid Manufacturing of Conformal Cooling Channels for Tooling

Feldhausen

Paramanathan

Heineman

et al. 2023

JMMP

View full text Add to dashboard Cite

Computer-aided manufacturing (CAM) techniques for hybrid manufacturing have led to new application areas in the manufacturing industry. In the tooling industry, cooling channels are used to enable specific heating and cooling cycles to improve the performance of the process. These internal cooling channels have been designed with limited manufacturing processes in mind, so, until recently, they were often straight in shape for cross-drilling operations and manufactured from a cast billet. To show a novel application of this common technology, a tool with integrated conformal cooling channels was manufactured using hybrid manufacturing (blown-powder DED and CNC machining) techniques. The computer-aided manufacturing strategy used, and the lessons learned are presented and discussed to enable future work in this industrial application space.

show abstract

Hybrid layered manufacturing of a bimetallic injection mold of P20 tool steel and mild steel with conformal cooling channels

Cited by 16 publications

References 29 publications

On the Features of Composite Coating, Based on Nickel Alloy and Aluminum–Iron Bronze, Processed by Direct Metal Deposition

On the Features of Composite Coating, Based on Nickel Alloy and Aluminum–Iron Bronze, Processed by Direct Metal Deposition

Hybridization in wire arc additive manufacturing

Hybrid Manufacturing of Conformal Cooling Channels for Tooling

Contact Info

Product

Resources

About