Development of a New Powder Mix and Process Plan to 3D Print Ductile Iron Parts

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CGL Manufacturing Inc. (CGL) is a proud supplier of machined castings, fabrications, and assemblies for top brands in the rail, material handling, construction, forestry, mining, heavy truck, agriculture, and defenseindustries. For its sample process, CGL provides its customers with cast metal parts, however, the castpreparation is time consuming. Additive Manufacturing (AM) also known as 3D printing is an opportunity to reduce the sample turnaround and production time. CGL provides parts to customers as cast (ductile) iron,however, this is not a metal conventionally produced with AM. Therefore, significant testing and iterations are required for the metal powder, AM process, and post-processing to produce a sample product with similarmechanical characteristics to a cast iron part.Mohawk College and the University of Guelph have the expertise, AM machinery, materials testing, andmetals expertise to develop metal powder, AM parameters and post production process to create sample parts that suit CGL and their client's needs. The University of Guelph and Mohawk College have collaborated on a prior NSERC- and Ontario Centres of Excellence-funded project to perform early investigations of thepotential for AM to replicate cast iron.The project will help to develop the market for ductile iron powder for AM, and to completely transform CGL'ssample part production process. The project results will help to de-risk additive manufacturing and supportCGL's innovation agenda goals. This project is combining advanced manufacturing strategies with parameter adjustments, data analyses and iterations to create a valuable business solution that will save CGL significant time in its sample production. Students will be trained and given valuable research and industry experiences at a College and University level in a unique multi institution and multidisciplinary project for an importantOntario manufacturer with CGL in Guelph, Ontario.