Optimization of selective laser melting for application to automotive tooling

Exco Engineering是一家位于安大略的世界领先的高压压铸模具设计和制造公司，最近启动了重大研发，采用增材制造（AM）生产模具和模具。AM是指一类工业技术，直接从数字化几何图形逐层构建对象，而不是减法或成形制造方法。人们相信，AM将打破目前的制造工艺，由于其独特的优势，在创造复杂的内部结构不可能产生的传统机械加工。在高压压铸中，增材制造能够将与最终部件轮廓相匹配的复杂冷却通道集成到钢模具中，从而改善热管理，最终提高质量、生产率和模具寿命。通过这种学术界和工业界的合作伙伴关系，我们旨在开发技术知识，以改善工具钢应用中金属增材制造的三个方面：再现性、高质量工艺窗口和成本。具体来说，我们将（1）表征粉末尺寸和形态，以了解重复使用时间的影响;（2）优化工艺参数，以减少构建时间，同时保持所需的机械性能;（3）研究混合制造，其中关键部分，如具有保形冷却的部分，被3D打印到现有的散装组件上。该项目将使Exco工程保持在工具/模具行业的竞争优势，保留就业机会并增加收入，同时为McMasters研究团队提供与金属AM工业应用相关的新知识和经验，以及这种新兴和关键的新制造技术的服务行为。

Exco Engineering, an Ontario based world leader in the design and fabrication of tooling for high pressure die casting, has recentlyinitiated significant R&D to adopt Additive Manufacturing (AM) for producing molds and dies. AM refers to a class of industrialtechnologies that build objects layer-by-layer directly from digitized geometry as opposed to subtractive or formative manufacturingmethods. It is believed that AM will disrupt current manufacturing processes due to its distinct advantages in creating complexinternal structures impossible to produce by conventional machining. In high pressure die casting, AM enables complex coolingchannels that match the profile of the final component to be integrated into the steel die, improving thermal management andultimately improving quality, production rates, and die longevity.Through this academic-industry partnership, we aim to develop technical knowledge to improve three aspects of metal AM for toolsteel applications: reproducibility, process window for high quality, and costs. Specifically, we will (1) characterize powder size andmorphology to understand the effects of reuse times; (2) optimize process parameters to reduce build time while maintainingdesired mechanical properties; and (3) investigate hybrid manufacturing whereby critical sections such as those with conformalcooling are 3D printed onto an already existing bulk component. This project will enable Exco Engineering to maintain competitiveadvantage in the tool/die industry, retaining jobs and increasing revenue, while providing McMasters research team with newknowledge and experience related to the industrial application of metal AM, and in-service behaviour of this emerging and key newmanufacturing technology.