The Fraunhofer Institute for Laser Expertise ILT has partnered with powder producer MacLean-Fogg and Toyota to develop a 3D printing answer for manufacturing massive die casting molds utilized in automotive manufacturing. The collaboration addresses the automotive trade’s shift towards fewer, extra complicated structural parts that require bigger and extra sturdy casting instruments with shorter improvement instances.
The challenge 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 contains a movable processing head, native shielding fuel steering, 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 situations.
Earlier makes an attempt to 3D print massive die casting molds confronted two foremost obstacles: inadequate construct volumes in standard machines and materials limitations with conventional device steels. Massive parts exceeding 20,000 cm³ in quantity sometimes skilled cracking, thermal distortion, and poor mechanical properties throughout each the printing course of and subsequent warmth therapy.
“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 Expertise at Fraunhofer ILT. “It was exactly this mixture that was the topic of the newest adjustments we now have applied.”
The challenge makes use of MacLean-Fogg’s L-40 metal, which was developed particularly for additive manufacturing purposes. The fabric demonstrates lowered cracking tendency in comparison with standard device steels and achieves 48 HRC hardness, 1420 MPa tensile energy, and over 60 J notched impression 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 device inlay with a quantity exceeding 20,000 cm³ and dimensions of 515 x 485 x 206 mm³. The expertise permits the creation of complicated inner cooling constructions that can’t be manufactured by way of standard processes, doubtlessly extending device service life in comparison with conventional molds.
Supply: ilt.fraunhofer.de
