State-of-the-art Laser Additive Manufacturing for Hot-work Tool Steels

Klocke, Fritz; Arntz, Kristian; Teli, Mahesh; Winands, Kai; Wegener, M.; Oliari, Stella

doi:10.1016/j.procir.2017.03.073

Cited by 83 publications

(38 citation statements)

References 22 publications

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“…Some processes have already been developed to additive manufacture metallic components, namely, direct metal deposition (DMD), laser engineered net shaping (LENS), selective laser melting (SLM), laser metal deposition (LMD), direct light fabrication (DLF), electron beam melting (EBM), among others [2]. Laser beam is especially used as an energy source in AM process for metals due to controllable heat input mechanisms [3].…”

Section: Additive Manufacturing Of H11 With Wire-based Laser Metal Dementioning

confidence: 99%

“…A variety of AM technologies is adopted in order to manufacture visual aids, presentation models, patterns for prototyping tooling and patterns for metal casting. The most common non-metallic materials used in these processes are epoxy resin, acrylate (polyjet), paper, rubber and polyester [2]. The favorable use of polymers is related to their low melting point and high viscosity which do not require complex heat input mechanisms and nozzle designs to produce parts [3].…”

Section: Introductionmentioning

confidence: 99%

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Additive Manufacturing of H11 with Wire-Based Laser Metal Deposition

2017

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Laser additive manufacturing (LAM) is a near-net-shape production technique by which a part can be built up from 3D CAD model data, without material removal. Recently, these production processes gained attention due to the spreading of polymer-based processes in private and commercial applications. However, due to the insufficient development of metal producing processes regarding design, process information and qualification, resistance on producing functional components with this technology is still present. To overcome this restriction further studies have to be undertaken. The present research proposes a parametric study of additive manufacturing of hot work tool steel, H11. The selected LAM process is wire-based laser metal deposition (LMD-W). The study consists of parameters optimization for single beads (laser power, travel speed and wire feed rate) as well as lateral and vertical overlap for layer-by-layer technique involved in LMD process. Results show that selection of an ideal set of parameters affects substantially the surface quality, bead uniformity and bond between substrate and clad. Discussion includes the role of overlapping on the soundness of parts based on the height homogeneity of each layer, porosity and the presence of gaps. For the conditions tested it was shown that once the deposition parameters are selected, lateral and vertical overlapping determines the integrity and quality of parts processed by LAM. Key-words:Laser additive manufacturing; Hot work tool steel; Parametric study; LMD-W. Manufatura Aditiva do Aço Ferramenta H11 por Deposição Metálica de Arame a LaserResumo: Manufatura aditiva a laser é uma técnica de produção por camadas na qual uma peça pode ser produzida a partir de um modelo 3D sem remoção de material. Recentemente, esses processos ganharam atenção devido à disseminação de processos com polímeros em aplicações privadas e comerciais. Entretanto, devido ao desenvolvimento insuficiente da manufatura aditiva com metais há uma resistência na produção de componentes funcionais com esta tecnologia. Portanto, para superar essa limitação, o presente artigo propõe um estudo nos parâmetros de processo de deposição metálica de arame a laser (LMD-W) do aço ferramenta para trabalho a quente, H11. O estudo consiste na otimização de parâmetros para cordões individuais (potência do laser, velocidade de deslocamento e de alimentação do arame), bem como sobreposição lateral e vertical para a técnica de camada por camada envolvida no processo. Os resultados mostram que a seleção de um conjunto ideal de parâmetros afeta substancialmente a qualidade superficial, a uniformidade dos cordões e a aderência entre o substrato e o cordão. A discussão ainda inclui a função da sobreposição na estabilidade do processo em relação à homogeneidade da altura de cada camada, porosidade e presença de falhas. Foi comprovado que após a seleção dos parâmetros de deposição, a sobreposição lateral e vertical determina a integridade e qualidade das peças manufaturadas aditivamente. Palavras-chave:M...

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Section: Additive Manufacturing Of H11 With Wire-based Laser Metal Dementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Additive Manufacturing of H11 with Wire-Based Laser Metal Deposition

2017

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“…Investigation of hybrid additive manufacturing of maraging and tool steel has been already reported by several papers [37][38][39]49,61,65]. SLM / DMLS was used for 3D printing.…”

Section: Maraging and Tool Steelsmentioning

confidence: 99%

Hybrid additive manufacturing of steels and alloys

Popov

Fleisher

2020

Manufacturing Rev.

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Hybrid additive manufacturing is a relatively modern trend in the integration of different additive manufacturing techniques in the traditional manufacturing production chain. Here the AM-technique is used for producing a part on another substrate part, that is manufactured by traditional manufacturing like casting or milling. Such beneficial combination of additive and traditional manufacturing helps to overcome well-known issues, like limited maximum build size, low production rate, insufficient accuracy, and surface roughness. The current paper is devoted to the classification of different approaches in the hybrid additive manufacturing of steel components. Additional discussion is related to the benefits of Powder Bed Fusion (PBF) and Direct Energy Deposition (DED) approaches for hybrid additive manufacturing of steel components.* e-mail: vvp@technion.ac.il Rev. 7, 6 (2020) This is an Open Access article distributed under the terms of the Creative Commons Attribution License (https://creativecommons.org/licenses/by/4.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. Manufacturing

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“…Four widely used cladding materials have been used to observe the change of residual stresses on the H13 tool steel substrate which is a popular material for tooling application [17]. This technique provides a unique method to compare residual stresses for different cladding materials, with capabilities to integrate material properties.…”

Section: 202 Page 2 Ofmentioning

confidence: 99%

An analytical model to predict and minimize the residual stress of laser cladding process

et al. 2018

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Laser cladding is one of the advanced thermal techniques used to repair or modify the surface properties of high-value components such as tools, military and aerospace parts. Unfortunately, tensile residual stresses are generated in the thermally treated area of this process. This work focuses on to investigate the key factors for the formation of tensile residual stress and how to minimize it in the clad when using dissimilar substrate and clad materials. To predict the tensile residual stress, a onedimensional analytical model has been adopted. Four cladding materials (Al 2 O 3 , TiC, TiO 2 , ZrO 2 ) on the H13 tool steel substrate and a range of preheating temperatures of the substrate, from 300 to 1200 K, have been investigated. Thermal strain and Young's modulus are found to be the key factors of formation of tensile residual stresses. Additionally, it is found that using a preheating temperature of the substrate immediately before laser cladding showed the reduction of residual stress.

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State-of-the-art Laser Additive Manufacturing for Hot-work Tool Steels

Cited by 83 publications

References 22 publications

Additive Manufacturing of H11 with Wire-Based Laser Metal Deposition

Additive Manufacturing of H11 with Wire-Based Laser Metal Deposition

Hybrid additive manufacturing of steels and alloys

An analytical model to predict and minimize the residual stress of laser cladding process

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