Case Study of Large Three-Dimensional-Printed Slider with Conformal Cooling for High-Pressure Die Casting.

Metal three-dimensional (3D) printing technology brings several benefits to the field of high-pressure die casting of aluminum, which enhances its development. The associated conformal cooling application is already commonly used where there is a need to improve the quality of castings, increase tool life, or reduce the production cycle. However, will this technology withstand the production of a large part (∼270 × 270 × 200 mm), which will be used directly in the serial production of engine blocks? This article describes a slider with a conformal cooling case study, which was redesigned and manufactured using the laser powder bed fusion (L-PBF) method. After the slider was put into serial production of 1.0 TSI three-cylinder engine blocks, this tool was thoroughly monitored based on the temperature field by comparing the results of a simulation in SW ProCAST with reality, and furthermore examining the influence of the tool on the quality of castings. There was also an evaluation of repairs performed on the tool in the SKODA AUTO tool shop and the foundry. These data were compared with a serial tool. Finally, the costs to produce the slider in conventional and 3D-printed variants are compared with an outline of other possible steps for optimizing these costs. The study results show that relatively large parts can be printed and used in serial production even today. It was also confirmed that conformal cooling influenced improving tool life, and the number of repairs in SKODA AUTO production also decreased.

Overview and Comparison of PLA Filaments Commercially Available in Europe for FFF Technology.

This study presents a comprehensive techno-economic analysis of PLA materials for fused filament fabrication (FFF) from eight European manufacturers. The comparison involved rigorous experimental assessments of the mechanical properties, dimensional accuracy, and print quality using standardized methods and equipment such as tensile and CT testing. What makes this study unique is the consistent methodology applied, considering factors such as material color, printing temperature, printing orientation, filament diameter, and printer selection, to ensure meaningful and reliable results. Contrary to the common belief that a higher price implies better quality, the study revealed that the second cheapest PLA material achieved the best overall performance within the methodology employed. The study also confirmed certain observations, such as the influence of printing orientation and geometry on dimensional accuracy and mechanical properties, as well as the significant disparities between manufacturer-provided values and actual measured mechanical properties, highlighting the importance of experimental verification. Hence, the findings of this study hold value not only for the scientific community but also for hobbyist printers and beginners in the 3D printing realm seeking guidance in material selection for their projects. Furthermore, the methodology employed in this research can be adapted for evaluating a broad range of other 3D printing materials.

Microstructure, Mechanical and Wear Behaviour of Deep Cryogenically Treated EN 52 Silchrome Valve Steel.

This study has compared the performance of cryogenically processed EN 52 Silchrome valve steel with untreated material. After completing the standard heat treatment process, EN 52 steel material specimens are subjected to a deep cryogenic process with varying soaking temperatures. The parameters of the deep cryogenic procedure were changed to find the best wear qualities. The key features of valve steel, such as microstructure, mechanical, and wear behaviour are evaluated by conducting a test study. The evolution of wear mechanisms after enhancing qualities of EN 52 steel is studied using scanning electron microscopy. The mechanical and wear behaviour improved due to factors such as fine carbide precipitation, conversion of residual austenite, and carbide refining formed after cryogenic treatment. With a maximum reduction in wear rate of up to 45%, the deep cryogenic treatment of EN 52 steel with a soaking temperature of -140 °C was the ideal parameter. All three cryo-treated samples had better properties than the untreated EN 52 valve steel.

Mechanical and Microstructural Anisotropy of Laser Powder Bed Fusion 316L Stainless Steel.

This paper aims at an in-depth and comprehensive analysis of mechanical and microstructural properties of AISI 316L austenitic stainless steel (W. Nr. 1.4404, CL20ES) produced by laser powder bed fusion (LPBF) additive manufacturing (AM) technology. The experiment in its first part includes an extensive study of the anisotropy of mechanical and microstructural properties in relation to the built orientation and the direction of loading, which showed significant differences in tensile properties among samples. The second part of the experiment is devoted to the influence of the process parameter focus level (FL) on mechanical properties, where a 48% increase in notched toughness was recorded when the level of laser focus was identical to the level of melting. The FL parameter is not normally considered a process parameter; however, it can be intentionally changed in the service settings of the machine or by incorrect machine repair and maintenance. Evaluation of mechanical and microstructural properties was performed using the tensile test, Charpy impact test, Brinell hardness measurement, microhardness matrix measurement, porosity analysis, scanning electron microscopy (SEM), and optical microscopy. Across the whole spectrum of samples, performed analysis confirmed the high quality of LPBF additive manufactured material, which can be compared with conventionally produced material. A very low level of porosity in the range of 0.036 to 0.103% was found. Microstructural investigation of solution annealed (1070 °C) tensile test samples showed an outstanding tendency to recrystallization, grain polygonization, annealing twins formation, and even distribution of carbides in solid solution.

Experimental Investigation of Suitable Cutting Conditions of Dry Drilling into High-Strength Structural Steel.

Dry machining is one of the main ways to reduce the environmental burden of the machining process and reduce the negative effect of the cutting fluid and aerosols on operators. In addition, dry machining can reduce overall machining costs and, in the case of large workpieces, reduce the extra work associated with removing residual cutting fluid from the workpiece and adjacent area. For high-strength structural steel products, it is typical to drill holes with larger diameters of around 20 mm. Therefore, this work is devoted to the investigation of the dry drilling process carried out on a workpiece made of S960QL steel with a helical drill with a diameter of 21 mm. The aim was to find suitable cutting conditions for dry drilling with regard to process stability and workpiece quality. An experiment performed with a coolant served as a comparison base. A dry drilling experiment was performed with cutting speeds from 30 to 70 m·min-1 and feeds from 0.1 to 0.3 mm·rev-1, and with the results of this experiment, the same experiment with flood cooling was performed. During the drilling process, spindle torque values were recorded using the indirect spindle current recording method. The macroscopic chip morphology was studied to understand the cutting process. The chip thickness ratio was measured, as well as the maximum diameter of spiral chips. On the final workpiece, the qualitative and dimensional parameters of the holes were evaluated, such as the diameter, cylindricity and surface roughness, depending on the change in the cutting conditions and cutting environment. Evaluation of the obtained data led to the following conclusions. When drilling the S960QL material, there is only a very small increase in the drilling torque during dry drilling compared to drilling with cutting fluid. The increase in friction demonstrated by the chip thickness coefficient is significant. The influence of the environment on the dimensional accuracy showed a tendency for a slight increase in the holes' diameters during dry machining. In comparison, the cylindricity of the dry-drilled holes shows a lower deviation than the holes drilled with cutting fluid. The surface roughness of the holes after dry drilling is affected by the increased friction of the outgoing chips, despite the resulting parameters being very good due to the drilling technology standards. This work provides a comprehensive view of the dry drilling process under defined conditions, and the results represent suitable cutting conditions to achieve a stable cutting process and a suitable quality of drilled holes.

Optimization of Process Parameters for Additively Produced Tool Steel 1.2709 with a Layer Thickness of 100 µm.

The purpose of this study was to find and optimize the process parameters of producing tool steel 1.2709 at a layer thickness of 100 µm by DMLS (Direct Metal Laser Sintering). HPDC (High Pressure Die Casting) tools are printed from this material. To date, only layer thicknesses of 20-50 µm are used, and parameters for 100 µm were an undescribed area, according to the state of the art. Increasing the layer thickness could lead to time reduction and higher economic efficiency. The study methodology was divided into several steps. The first step was the research of the single-track 3D printing parameters for the subsequent development of a more accurate description of process parameters. Then, in the second step, volume samples were produced in two campaigns, whose porosity was evaluated by metallographic and CT (computed tomography) analysis. The main requirement for the process parameters was a relative density of the printed material of at least 99.9%, which was achieved and confirmed using the parameters for the production of the samples for the tensile test. Therefore, the results of this article could serve as a methodological procedure for optimizing the parameters to streamline the 3D printing process, and the developed parameters may be used for the productive and quality 3D printing of 1.2709 tool steel.