Metal Additive Manufacturing Conference - MAMC 2020

3D printed components and tools operate under severe conditions that often require additional surface protection and functionality. In order to increase the lifetime and endurance of 3D printed components used for forming of metal parts in the automotive sector, the present paper proposes their functionalization using multifunctional coatings with increased wear resistance and friction control. The 3D printed tools are made of Maraging Steel (EOS MS1, 1.2709) by Laser Beam Melting technology, an additive manufacturing process in which 3D parts are created by consolidating pre-spread powders in a layer-by-layer way. Afterwards, multifunctional coatings are applied by means of laser cladding using a high-power direct diode laser. The resulting claddings provide wear resistance, self-lubrication and oxidation resistance, thus increasing the life span of metal tools and reducing expensive maintenance costs. The functionalized 3D printed tools are investigated for prospective forming of aluminium sheets at high temperatures (300-400°C). To this end, a forming tribometer is utilized paying special attention to the use of realistic forming parameters and short times for having mostly fresh workpiece in contact with the tool, in analogy with forming processes. Prior to the experiments, solid lubricant (graphite-based) is applied to the claddings in order to reduce adhesion with the aluminium counterpart. With the aim of online monitoring of the process conditions, the work also focusses on the integration of sensors in such 3D printed multifunctional tools. As an example, conductivity sensors for determination of tribological relevant parameters (like tension, pressure, acceleration) signalizing for e.g. high friction forces can be listed. The online monitoring assured by the sensors is expected to open doors to new fields of application. Vibration sensors indicating local defects of lubrication are a major focus of development to allow integrated “end of life” or service/maintenance indication.