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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Article continued from page 15. checking and wear damages during forging, the tool was built using low-cost steel, and a high-temperature Co-based alloy was applied in the heat checking areas. In contrast to the mechanical bonding of the CVD/PVD/thermal spray coatings, DMD material is metallurgically bonded to the base steel and can withstand the thermal and fatigue loading of the A B Bi-Met tooling: Figure 3 shows an injection molding tool used for making seatbelt clamps for cars. Te tool has been manufactured using DM3D Technology's proprietary Bi-Met tooling technology where tool steel is cladded on a copper base using the DMD process. High thermal conductivity of the copper base (six times C D Figure 2. DMD cladding of connecting rod forging tool. (A) CAD model showing tool base and DMD coating, (B) DMD process in action, (C) DMD deposited tool and (D) fnish machined tool. A B that of steels) allows faster heat transfer, leading to a 40-percent reduction in cycle time, while the steel clad on the molding surface provides the required strength and wear resistance of the tool. Conclusions Figure 3. (A) Steel-cladded copper tool for car seat belt and (B) cross section microstructure of steel cladding on copper alloy with an intermediate bufer layer. forging process without chipping of the coating material. DMD-built hardfacing material was about 6-mm thick to sustain severe forging pressure and also allow for remachining of the tool multiple times. DMD-applied tools had four times longer life over conventional tooling and resulted in signifcant cost savings while reducing downtime. 16 — AM Supplement DMD technology ofers fully dense, metallurgically bonded, protective coatings on parts with complex geometries. Its ability to deliver multiple materials allows it to create graded cermet coatings and/or application of diferent metals in diferent places. Application of the technology can produce signifcant cost savings through improved performance and productivity. For more information about additive technologies, contact Tim Shinbara, Technical Director, AMT–Te Association for Manufacturing Technology, at tshinbara@AMTonline.org or 703-827-5243.

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