Selective laser melting (SLM) is a new technology gaining popularity in the toolmaking world. It allows us to produce complex geometries that previously could not be achieved with conventional manufacturing methods. This is particularly evident in the production of tool components with a conformal cooling-heating system to optimize the pressure die casting process.
The thesis describes the construction process and the challenges faced during the manufacturing of these components with conformal cooling to achieve optimal cooling. The aim was to optimize the casting process by implementing a conformal cooling-heating system in the core of the side insert. This was compared to a core that contained channels made using traditional drilling and plugging methods.
Numerical simulations were used to calculate the casting processes using the FDM method (finite difference method). Specifically, we calculated temperature fields, stress fields, compared flow rates, and analysed the likelihood of soldering.
We thoroughly familiarized ourselves with the SLM (Selective Laser Melting) 3D printing process, where we printed maraging steel MS1 onto a substrate made of H13 tool steel. Subsequently, we manufactured and thermally treated test specimens to verify the joining of the two laser-welded materials. This involved ultrasonic analysis of the joint, tensile strength testing, toughness testing, hardness testing, and microstructure analysis. The purpose was to demonstrate the viability of using a hybrid printing method to reduce production costs.
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