PSI - Issue 54

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ScienceDirect

Procedia Structural Integrity 54 (2024) 568–574 Structural Integrity Procedia 00 (2023) 000–000 Structural Integrity Procedia 00 (2023) 000–000

www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia

2452-3216 © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the ICSI 2023 organizers 10.1016/j.prostr.2024.01.120 ∗ Corresponding author. Tel.: +351 229578710 ; fax: +351 229537352. E-mail address: dbraga@inegi.up.pt 2210-7843 © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/) Peer-review under responsibility of the scientific committee of the ICSI 2023 organizers. 1. Introduction The transformative potential of metal additive manufacturing (AM) has redefined the landscape of mod ern manufacturing, offering unparalleled design freedom, rapid prototyping capabilities, and the promise of innovative, complex components. Among the multitude of metal AM techniques, the convergence of Selec tive Laser Melting (SLM) and Laser Metal Deposition (LMD) stands as a pioneering approach, propelling the technology into new dimensions. Although powder-bed based technologies like SLM enable optimized, high geometric complexity parts to be manufactured, low build-up rates and systems print volumes limit component sizes and feasibility of many applications. The synergies between SLM and LMD offer a unique ∗ Corresponding author. Tel.: +351 229578710 ; fax: +351 229537352. E-mail address: dbraga@inegi.up.pt 2210-7843 © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/) Peer-review under responsibility of the scientific committee of the ICSI 2023 organizers. © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0 ) Peer-review under responsibility of the scientific committee of the ICSI 2023 organizers Abstract Metal additive manufacturing (AM) and especially direct energy deposition (DED) through laser metal deposition (LMD), enables economically viable, high performance, optimized components, such as, nickel alloy complex geom etry turbine blades. Also, when combined with complementing technologies such as selective laser melting (SLM) and various post processing techniques, advanced products in less technological intensive industries may also be developed with added value features. One example of such is tooling for high temperature forming, with integrated optimized cooling and simultaneous high wear resistance surfaces. However, these AM processes result in complex microstructures which affect their mechanical performance, especially given the demanding loading scenarios which the applications they are designed for require. This study makes use of Design of Experiments (DoE) approach to study the effect of LMD process parameters on hybrid SLM-LMD tool steel components strength, towards the application of this hybrid manufacturing approach in hot forming tooling. © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/) Peer-review under responsibility of the scientific committee of the ICSI 2023 organizers. Keywords: Additive Manufacturing; Design of Experiments; Direct Energy Deposition 1. Introduction The transformative potential of metal additive manufacturing (AM) has redefined the landscape of mod ern manufacturing, offering unparalleled design freedom, rapid prototyping capabilities, and the promise of innovative, complex components. Among the multitude of metal AM techniques, the convergence of Selec tive Laser Melting (SLM) and Laser Metal Deposition (LMD) stands as a pioneering approach, propelling the technology into new dimensions. Although powder-bed based technologies like SLM enable optimized, high geometric complexity parts to be manufactured, low build-up rates and systems print volumes limit component sizes and feasibility of many applications. The synergies between SLM and LMD offer a unique Abstract Metal additive manufacturing (AM) and especially direct energy deposition (DED) through laser metal deposition (LMD), enables economically viable, high performance, optimized components, such as, nickel alloy complex geom etry turbine blades. Also, when combined with complementing technologies such as selective laser melting (SLM) and various post processing techniques, advanced products in less technological intensive industries may also be developed with added value features. One example of such is tooling for high temperature forming, with integrated optimized cooling and simultaneous high wear resistance surfaces. However, these AM processes result in complex microstructures which affect their mechanical performance, especially given the demanding loading scenarios which the applications they are designed for require. This study makes use of Design of Experiments (DoE) approach to study the effect of LMD process parameters on hybrid SLM-LMD tool steel components strength, towards the application of this hybrid manufacturing approach in hot forming tooling. © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/) Peer-review under responsibility of the scientific committee of the ICSI 2023 organizers. Keywords: Additive Manufacturing; Design of Experiments; Direct Energy Deposition International Conference on Structural Integrity 2023 (ICSI 2023) Hybrid Selective Laser Melting, Direct Energy Deposition process strength-based optimization for Hot-Forming Tool Daniel F.O. Braga a, ∗ , Lucas Azevedo b , G. Cipriano a , Pedro M.G.P. Moreira a a INEGI, Campus da FEUP, Universidade Do Porto, Rua Dr. Roberto Frias, 400, 4200-465, Porto, Portugal b Quantal S. A., Rua São Cristóvão, 95, 4480-430, Rio Mau, Vila do Conde, Portugal International Conference on Structural Integrity 2023 (ICSI 2023) Hybrid Selective Laser Melting, Direct Energy Deposition process strength-based optimization for Hot-Forming Tool Daniel F.O. Braga a, ∗ , Lucas Azevedo b , G. Cipriano a , Pedro M.G.P. Moreira a a INEGI, Campus da FEUP, Universidade Do Porto, Rua Dr. Roberto Frias, 400, 4200-465, Porto, Portugal b Quantal S. A., Rua São Cristóvão, 95, 4480-430, Rio Mau, Vila do Conde, Portugal