Additive Manufacturing of Hot-Forming Dies Using Laser Powder Bed Fusion and Wire Arc Direct Energy Deposition Technologies

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Abstract

Additive technologies are now widely used for the production of complex precise parts and have high potential for the production of forming dies. In this work, hot-forming dies optimized for additive manufacturing were developed and produced with wire arc direct energy deposition (WA-DED) and laser powder bed fusion (L-PBF) technologies. The concept of lightweight hot-forming dies with a 2D-lattice structure was developed, which reduced the weight of each die by 56%, from 14.2 kg to 6.1 kg, in production using L-PBF. Maraging/precipitation-hardened steel 17-4PH was used as an alternative to traditional hot-working steels with slightly lower mechanical properties and a much higher processability in the additive manufacturing process. The workability of the manufactured dies was confirmed by forging tests on an industrial screw press.

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Alimov, A., Sviridov, A., Sydow, B., Jensch, F., & Härtel, S. (2023). Additive Manufacturing of Hot-Forming Dies Using Laser Powder Bed Fusion and Wire Arc Direct Energy Deposition Technologies. Metals, 13(11). https://doi.org/10.3390/met13111842

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