Sheet metal parts with integrated additive manufactured geometries

Purpose and goal:

The potential of a manufacturing process chain consisting of AM and hot forming has been demonstrated. The method imply sustainability gains with a reduction in number of necessary process steps and included items. For a component of commercial interest, the blank material, process for Laser-DED-wire and hot forming has been developed through process simulation (FEM).

Participating companies have successfully collaborated and identified future challenges concerning concepts for heating and material selection for hot forming tool components. Expected results and effects:

A number of demonstration components have been manufactured by AM, hot forming and machining. The predicted outcome regarding the AM process as well as the choice of process parameters for hot forming and shape deviation agree well with experimental tests. Challenges around tool material and concepts for heating in hot forming have been identified.

The hot forming process, which takes place at over 950 C, imply very high loads on the tool material. In this case the tool steel was deformed in an undesirable way. Approach and implementation:

The project has been carried out within work packages regarding the selection and design of demonstrator component, design of blank material, fixturing and process parameter for both AM and hot forming, FE modeling as well as technical aspects regarding final processing and evaluation. In a systematic way, the work has been carried out with mainly successful results.

The potential of the manufacturing chain has been demonstrated, although challenges remain regarding the heating method and tooling material. New project is intended to be formulated focusing on remaining challenges.