Characterization of metal powder based rapid prototyping components under aluminium high pressure die casting process conditions

Abstract

This paper is based on tests performed on die component specimens grown on an EOS RP technology platform, as well as manufactured specimens machined out of preferred standard hot work steel DIN 1.2344. These specimens resemble typical components used in metal high pressure die casting toolsets. The specimens were subjected to a program of cyclic immersion in molten aluminium alloy and cooling in water based die release medium. The heat checking and soldering phenomena were analyzed through periodic inspections, monitoring crack formation and evidence of surface washout. At the end of the thermal tests, mechanical strength and hardness tests were performed to assess toughness and core resistance variations in relation to the initial conditions. Finally metallographic investigations were performed through optical microscopy on all the specimens considered. The outcomes of this research will be presented and used by the CSIR for further development and application of the assessed RP technology in rapid die manufacturing techniques, die design principles, including time and economic feasibility criteria to be applied when considering rapid die manufacture.