Scaling Up metal additive manufacturing process to fabricate molds for composite manufacturing
Abstract
Direct Energy Deposition (DED) systems are currently used to repair and maintain existing parts in the aerospace and automotive industries. This paper discusses an effort to scale up the DED technique in order to Additively Manufacture (AM) molds and dies used in the composite manufacturing industry. The US molds and dies market has been in a rapid decline over the last decade due to outsourcing to non-US entities. Oak Ridge National Laboratory (ORNL), Wolf Robotics and Lincoln Electric have developed a Metal Big Area Additive Manufacturing (MBAAM) system that uses a high deposition rate and a low-cost wire feedstock material. In this work we used the MBAAM system with a mild steel wire, ER70S-6, to fabricate a compression molding mold for composite structures used in automotive and mass-transit applications. In addition, the mechanical properties of the AM structure were investigated, and it was found that the MBAAM process delivers parts with high planar isotropic behavior. The paper investigates the microstructure and grain of the printed articles to confirm the roots of the observed planar isotropic properties. Here, the manufactured AM mold was used to fabricate 50 composite parts with no observed mold deformations.
- Authors:
-
[1];
[1];
[1];
[1];
[1];
[1];
[1]
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
- Univ. of Tennessee, Knoxville, TN (United States)
- Publication Date:
- Research Org.:
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
- Sponsoring Org.:
- USDOE Office of Energy Efficiency and Renewable Energy (EERE)
- OSTI Identifier:
- 1607191
- Alternate Identifier(s):
- OSTI ID: 1602885
- Grant/Contract Number:
- AC05-00OR22725
- Resource Type:
- Accepted Manuscript
- Journal Name:
- Additive Manufacturing
- Additional Journal Information:
- Journal Volume: 32; Journal Issue: C; Journal ID: ISSN 2214-8604
- Publisher:
- Elsevier
- Country of Publication:
- United States
- Language:
- English
- Subject:
- 36 MATERIALS SCIENCE; Metal Big Area Additive Manufacturing (MBAAM); smart manufacturing; robotic welding; AM molds; MGAW
Citation Formats
Hassen, Ahmed Arabi, Noakes, Mark, Nandwana, Peeyush, Kim, Seokpum, Kunc, Vlastimil, Vaidya, Uday, Love, Lonnie, and Nycz, Andrzej. Scaling Up metal additive manufacturing process to fabricate molds for composite manufacturing. United States: N. p., 2020.
Web. doi:10.1016/j.addma.2020.101093.
Hassen, Ahmed Arabi, Noakes, Mark, Nandwana, Peeyush, Kim, Seokpum, Kunc, Vlastimil, Vaidya, Uday, Love, Lonnie, & Nycz, Andrzej. Scaling Up metal additive manufacturing process to fabricate molds for composite manufacturing. United States. https://doi.org/10.1016/j.addma.2020.101093
Hassen, Ahmed Arabi, Noakes, Mark, Nandwana, Peeyush, Kim, Seokpum, Kunc, Vlastimil, Vaidya, Uday, Love, Lonnie, and Nycz, Andrzej. Sat .
"Scaling Up metal additive manufacturing process to fabricate molds for composite manufacturing". United States. https://doi.org/10.1016/j.addma.2020.101093. https://www.osti.gov/servlets/purl/1607191.
@article{osti_1607191,
title = {Scaling Up metal additive manufacturing process to fabricate molds for composite manufacturing},
author = {Hassen, Ahmed Arabi and Noakes, Mark and Nandwana, Peeyush and Kim, Seokpum and Kunc, Vlastimil and Vaidya, Uday and Love, Lonnie and Nycz, Andrzej},
abstractNote = {Direct Energy Deposition (DED) systems are currently used to repair and maintain existing parts in the aerospace and automotive industries. This paper discusses an effort to scale up the DED technique in order to Additively Manufacture (AM) molds and dies used in the composite manufacturing industry. The US molds and dies market has been in a rapid decline over the last decade due to outsourcing to non-US entities. Oak Ridge National Laboratory (ORNL), Wolf Robotics and Lincoln Electric have developed a Metal Big Area Additive Manufacturing (MBAAM) system that uses a high deposition rate and a low-cost wire feedstock material. In this work we used the MBAAM system with a mild steel wire, ER70S-6, to fabricate a compression molding mold for composite structures used in automotive and mass-transit applications. In addition, the mechanical properties of the AM structure were investigated, and it was found that the MBAAM process delivers parts with high planar isotropic behavior. The paper investigates the microstructure and grain of the printed articles to confirm the roots of the observed planar isotropic properties. Here, the manufactured AM mold was used to fabricate 50 composite parts with no observed mold deformations.},
doi = {10.1016/j.addma.2020.101093},
journal = {Additive Manufacturing},
number = C,
volume = 32,
place = {United States},
year = {Sat Jan 25 00:00:00 EST 2020},
month = {Sat Jan 25 00:00:00 EST 2020}
}
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