Fraunhofer Institute for Laser Expertise (ILT), a German analysis group specializing in laser-based manufacturing, and MacLean-Fogg, a U.S. provider of engineered metallic elements, have produced a big die casting software inlay for Toyota utilizing laser powder mattress fusion (PBF-LB/M). The challenge marks the primary profitable demonstration of large-volume instruments with conformal cooling, made potential by a newly developed software metal referred to as L-40. A hybrid mildew insert for the Toyota Yaris Hybrid transmission housing was manufactured by combining standard preforms with additively constructed buildings, decreasing manufacturing time and enabling extra advanced cooling designs.
Automotive producers are beneath strain to consolidate elements into fewer however bigger aluminum elements as electrification and value competitors reshape automobile platforms. This shift locations greater calls for on die casting molds, which should resist excessive thermal and mechanical stresses whereas adapting rapidly to design adjustments. Conventional machining and gear steels akin to H11, H13, or M300 wrestle to ship these necessities at scale, main Fraunhofer ILT and MacLean-Fogg to concentrate on new machine ideas and supplies. Toyota, already utilizing smaller additively manufactured molds in collection manufacturing, has reported considerably longer software life in comparison with standard inserts, with service lives as much as 4 instances higher.
Niklas Prätzsch, Group Chief for LPBF Course of Expertise at Fraunhofer ILT, defined: “To beat these limitations, we want a brand new era of machines and supplies particularly tailor-made to the necessities of large-format HPDC instruments. It was exactly this mix that was the topic of the newest adjustments we have now applied.”
Fraunhofer ILT designed a gantry-based five-laser PBF-LB/M machine with a construct chamber measuring 1,000 × 800 × 350 mm³. In contrast to fixed-bed programs, the machine employs a movable processing head with native shielding gasoline steerage, holding parameters akin to gasoline circulation velocity and laser deflection angle fixed because the construct space scales. This strategy enabled development of inserts exceeding 20,000 cm³, together with the Toyota inlay with a bounding field of 515 × 485 × 206 mm³. A heated substrate reaching 200 °C lowered temperature gradients throughout the construct, reducing the danger of residual stress and cracking that usually happen in giant geometries.
Materials improvement was equally vital. MacLean-Fogg created L-40, a metal tailor-made for additive processing of high-pressure die casting instruments. In comparison with established alloys, L-40 confirmed a markedly decrease tendency to crack throughout each printing and warmth therapy. Within the as-built state, the alloy achieved hardness of 48 HRC, tensile energy of 1,420 MPa, and notched impression energy above 60 J. Checks confirmed stability in advanced geometries, together with spherical and overhanging cooling channels, the place standard steels typically fail.
For Toyota’s gearbox housing, the challenge crew adopted a hybrid manufacturing methodology. A preform with vertical cooling channels was first manufactured conventionally, after which conformal channels had been additively constructed on high. This required exact machine calibration to make sure correct alignment and dependable bonding between the 2 sections. After completion, the insert was stress-relief annealed and its practical surfaces had been milled conventionally. Excessive dimensional accuracy within the additive base physique meant solely minimal ending was wanted with out additional materials enter.
Harald Lemke, Director of Product Administration at MacLean-Fogg Element Options, stated: “With L-40, we got down to break the bounds of additive manufacturing for cold and warm forming instruments typically and die casting instruments particularly. This challenge proves that it’s potential to supply giant, advanced and extremely sturdy inserts technically and offers clear milestones to succeed in to be economically enticing. Additive manufacturing is able to tackle actual industrial scale challenges.”
The conformal cooling community throughout the insert was designed to mood thermally harassed zones of the mildew. By reducing native temperature peaks, the system reduces thermomechanical put on and extends service life. Earlier research confirmed additive molds lasting as much as 4 instances longer than standard H13 inserts, and the present challenge scaled these benefits to bigger functions. For producers, this implies fewer software replacements, decrease prices, and sooner response instances to new design necessities.
Past automotive die casting, the method chain is relevant to different areas requiring sturdy instruments with advanced cooling. Potential extensions embrace plastics processing and composite forming, the place restricted batch sizes and excessive thermal hundreds additionally drive the necessity for extra resilient molds. With giga casting and electrified automobile platforms elevating tooling calls for additional, scalable additive programs supply a path towards sooner, extra adaptable, and longer-lasting manufacturing instruments.
Restricted areas stay for AMA:Vitality 2025. Register now to hitch the dialog on the way forward for power and additive manufacturing.
Prepared to find who received the 2024 3D Printing Trade Awards?
Subscribe to the 3D Printing Trade publication and comply with us on LinkedIn to remain up to date with the newest information and insights.
Featured picture exhibits the additively manufactured aluminum die-cast software is a part of the software for the transmission housing of the Toyota Yaris hybrid automobile. Picture through Toyota Europe.
