Speaker
Description
Die forging is a manufacturing process for the industrial and economical serial production of metal components. Forging dies are subject to high mechanical, thermal, tribological and chemical loads. These loads can lead to deterioration of the tool surface in form of abrasive wear, plastic deformation and crack formation. The reduction of tool wear and increase of tool lifetime are major challenges for tool development. A promising strategy for reducing tool wear is to lower the maximum tool temperature to counteract softening of the tool surface layer. As a result of a reduced maximum temperature, the temperature gradient is reduced, which is expected to improve the thermal cracking behavior.
In this study, the additive manufacturing process selective laser melting is used to fabricate wear-resistant tool areas of forging dies with internal cooling channels. The hybrid tool design allows a cost-effective fabrication of small build-up volume and an integration of conformal cooling channels with complex shapes to control the temperature during the forming process. Conventional manufacturing processes cannot produce these conformal cooling channels. Thus, gas-atomised hot work tool steel powder H10 is used to build up the complex geometries of the forging dies. The powder material is used on commercially available machines with different parameter settings. Within the scope of this study, these parameter settings and the process-induced defects are discussed. The as-built microstructure and the material specific heat treatment strategy of the additive fabricated H10 tool steel are presented. In addition, the relative density of H10 tool steel is determined and the powder preheating temperature is adapted to achieve a crack-free fabrication of H10 tool steel. Numerical simulation is applied to evaluate the mechanical loads of different designs of the fabricated hybrid forging tools and to investigate them in relation to critical tool areas.
| Speaker Country | Austria |
|---|