The Fraunhofer Institute for Laser Know-how ILT has partnered with powder producer MacLean-Fogg and Toyota to develop a 3D printing resolution for manufacturing massive die casting molds utilized in automotive manufacturing. The collaboration addresses the automotive trade’s shift towards fewer, extra complicated structural elements that require bigger and extra sturdy casting instruments with shorter improvement occasions.
The mission facilities on a gantry-based powder mattress fusion laser beam melting (PBF-LB/M) machine with a scalable construct quantity of 1,000 x 800 x 350 mm³. The system incorporates a movable processing head, native shielding gasoline steerage, and a heatable substrate module that reaches 200°C to attenuate temperature gradients throughout manufacturing. This design permits the construct quantity to be scaled linearly whereas sustaining constant course of circumstances.
Earlier makes an attempt to 3D print massive die casting molds confronted two major obstacles: inadequate construct volumes in typical machines and materials limitations with conventional instrument steels. Massive elements exceeding 20,000 cm³ in quantity usually skilled cracking, thermal distortion, and poor mechanical properties throughout each the printing course of and subsequent warmth remedy.
“To beat these limitation, we want a brand new technology of machines and supplies particularly tailor-made to the necessities of large-format HPDC instruments,” explains Niklas Prätzsch, Group Chief LPBF Course of Know-how at Fraunhofer ILT. “It was exactly this mixture that was the topic of the newest modifications we have now carried out.”
The mission makes use of MacLean-Fogg’s L-40 metal, which was developed particularly for additive manufacturing functions. The fabric demonstrates diminished cracking tendency in comparison with typical instrument steels and achieves 48 HRC hardness, 1420 MPa tensile energy, and over 60 J notched influence energy within the as-built situation. “The important thing to success lies within the L-40 materials from MacLean-Fogg, which is tailor-made to the necessities of PBF-LB/M,” feedback Prätzsch.
The system efficiently produced a instrument inlay with a quantity exceeding 20,000 cm³ and dimensions of 515 x 485 x 206 mm³. The know-how allows the creation of complicated inside cooling constructions that can not be manufactured by typical processes, doubtlessly extending instrument service life in comparison with conventional molds.
Supply: ilt.fraunhofer.de
