Metal Additive Manufacturing Conference - MAMC 2024

Forging tools endure extreme conditions, being subjected to both high temperatures and mechanical stresses on their operational surfaces. Enhancing resistance to external influences is crucial for extending their service life. This paper investigates the efficacy of incorporating a material layer, manufactured via Additive Manufacturing using Directed Energy Deposition (DED), to bolster the durability of forging tools and dies. Specifically, it focuses on the application of a protective layer made from Nimonic 80A and a combination of Nimonic 80A and tungsten carbide material deposited on tool steel. The study encompasses comprehensive analyses, including powder characterization, determination of depositing parameters, evaluation of mechanical properties, and pin-on-disc measurements. Furthermore, Finite Element (FE) analysis is employed to simulate wear analysis processes.