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

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

PEDDINGHAUS Julius, SIEGMUND Martin, SIRING Janina, WESTER Hendrik, GIEDENBACHER Jochen, HUSKIC Aziz, BEHRENS Bernd-Arno, BRUNOTTE Kai

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Abstract. 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 [1]. 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.

Keywords
Additive Manufacturing, Forging, Wear Protection

Published online 4/24/2024, 10 pages
Copyright © 2024 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: PEDDINGHAUS Julius, SIEGMUND Martin, SIRING Janina, WESTER Hendrik, GIEDENBACHER Jochen, HUSKIC Aziz, BEHRENS Bernd-Arno, BRUNOTTE Kai, Potential of near-surface temperature regulation in hybrid additive manufactured forging dies, Materials Research Proceedings, Vol. 41, pp 891-900, 2024

DOI: https://doi.org/10.21741/9781644903131-97

The article was published as article 97 of the book Material Forming

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

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