Additive Manufacturing

AUG 2013

Modern Machine Shop and MoldMaking Technology present ADDITIVE MANUFACTURING, a quarterly supplement reporting on the use of additive processes to manufacture functional parts. More at additivemanufacturinginsight.com.

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Component and Tool Life Extension Using Direct Metal Deposition (DMD) By Bhaskar Dutta, DM3D Technology Introduction Direct metal deposition (DMD) is a proprietary laser additive manufacturing technology that ofers surface protective cladding and/or coating solutions to protect against wear and/or corrosion. With its closed-loop feedback system, fve-axis motion capability and DMDCAM 3D-software, DMD can clad/coat expensive, high-performance metals onto low-cost substrates of diferent geometries. Tis allows for substantial savings on material costs while improving performance of the parts. Process Overview An industrial laser beam under CNC/robotic control is focused onto a workpiece, producing a melt pool into which a small amount of powder metal is injected, building up the part in a thin layer. Te beam is moved to the next location based on CAD geometry, tracing out the part layer by layer. Some features of DMD systems are: patented closed-loop feedback control for the process that reduces heat Figure 1. (A) DMD hardfacing of an oil drilling tool with cermet in DMD505 and (B) microstructure of the hardfacing material showing 60-percent WC particles in a nickel alloy matrix. A B input; a patented coaxial nozzle with local shielding of the melt pool which allows consistent powder delivery and processing under an open atmosphere; six-axis DMDCAM software for additive manufacturing; fve-axis moving optics for heavy parts; and multi-material delivery capability. Application DM3D Technology (formerly POM Group) has developed a large proprietary material database for application in diferent environments. Tis includes components in automotive engines, the tool and die industry, the oil and gas industry, and many others. Some of the case studies are discussed here. DMD-applied cermet composite hardfacing: DMD has been widely applied in the area of hardfacing to provide improved resistance against wear in the oil and gas industry (Figure 1). Tis down hole tool was coated with cermet material containing 60 percent WC in a nickel alloy matrix. With its multi-material delivery capability, DMD can apply graded coatings on such tools ranging from a 10-percent WC coating on the part surface to 60 percent WC coating on the outermost surface. Te extended tool life adds signifcant cost savings. Additional cost benefts include inventory reduction and a reduction in downtime due to less-frequent tool changing, which results in increased productivity. Heat checking/wear coating: DMD is a value-added technology that has been successfully applied in forging/stamping tools with great advantages. Figure 2 shows such an example where a forging die for the connecting rod has been coated using the DMD process. To overcome the heat AdditiveManufacturingInsight.com August 2013 — 15

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