TY - GEN

T1 - Potential of near-surface temperature regulation in hybrid additive manufactured forging dies

AU - Peddinghaus, Julius

AU - Siegmund, Martin

AU - Siring, Janina

AU - Wester, Hendrik

AU - Giedenbacher, Jochen

AU - Huskic, Adis

AU - Behrens, Bernd-Arno

AU - Brunotte, Kai

N1 - Publisher Copyright: © 2024, Association of American Publishers. All rights reserved.

PY - 2024

Y1 - 2024

N2 - Recent advances in the field of additive manufacturing (AM) have enabled the utilisation of Laser Powder Bed Fusion (L-PBF) for tool steels under high load conditions. Design elements, such as internal cooling channels, which are not achievable through subtractive manufacturing can therefore be used to functionalise and optimise hot forging tools. Thermal control is crucial for hot forging dies as the performance and endurance of the tools is highly dependent on the input and dissipation of heat in the surface zone during forging. A modified forging tool with conformal internal cooling channels generated through a hybrid L-PBF manufacturing process was developed in prior work. The objective in the presented research is the experimental evaluation of the effect of conformal temperature control in the novel tool concept on the temperature dependent tool deterioration mechanisms in forging conditions. The actively controlled water temperature was varied between room temperature for maximum cooling and 180 °C, representing an exemplary base temperature in steady state serial forging. After 1,000 cycles, the tool wear conditions are analysed optically and through destructive microstructure analysis to characterise the effect of the temperature management on the deterioration mechanisms. The results show a significant impact of subsurface temperature control on the wear mechanisms of forging dies. Abrasive wear can be limited to a minimum through internal cooling with major reduction in thermal loads. Increased base temperatures reduce run-in time but increase abrasion.

AB - Recent advances in the field of additive manufacturing (AM) have enabled the utilisation of Laser Powder Bed Fusion (L-PBF) for tool steels under high load conditions. Design elements, such as internal cooling channels, which are not achievable through subtractive manufacturing can therefore be used to functionalise and optimise hot forging tools. Thermal control is crucial for hot forging dies as the performance and endurance of the tools is highly dependent on the input and dissipation of heat in the surface zone during forging. A modified forging tool with conformal internal cooling channels generated through a hybrid L-PBF manufacturing process was developed in prior work. The objective in the presented research is the experimental evaluation of the effect of conformal temperature control in the novel tool concept on the temperature dependent tool deterioration mechanisms in forging conditions. The actively controlled water temperature was varied between room temperature for maximum cooling and 180 °C, representing an exemplary base temperature in steady state serial forging. After 1,000 cycles, the tool wear conditions are analysed optically and through destructive microstructure analysis to characterise the effect of the temperature management on the deterioration mechanisms. The results show a significant impact of subsurface temperature control on the wear mechanisms of forging dies. Abrasive wear can be limited to a minimum through internal cooling with major reduction in thermal loads. Increased base temperatures reduce run-in time but increase abrasion.

KW - Additive Manufacturing

KW - Forging

KW - Wear Protection

UR - http://www.scopus.com/inward/record.url?scp=85195986725&partnerID=8YFLogxK

U2 - 10.21741/9781644903131-97

DO - 10.21741/9781644903131-97

M3 - Conference contribution

SN - 9781644903131

T3 - Materials Research Proceedings

SP - 891

EP - 900

BT - Materials Research Proceedings

A2 - Araujo, Anna Carla

A2 - Cantarel, Arthur

A2 - Chabert, France

A2 - Korycki, Adrian

A2 - Olivier, Philippe

A2 - Schmidt, Fabrice

ER -