Scaling Up metal additive manufacturing process to fabricate molds for composite manufacturing

Ahmed Arabi Hassen; Mark Noakes; Peeyush Nandwana; Seokpum Kim; Vlastimil Kunc; Uday Vaidya; Lonnie Love; Andrzej Nycz

doi:10.1016/j.addma.2020.101093

Scaling Up metal additive manufacturing process to fabricate molds for composite manufacturing

Ahmed Arabi Hassen, Mark Noakes, Peeyush Nandwana, Seokpum Kim, Vlastimil Kunc, Uday Vaidya, Lonnie Love, Andrzej Nycz

Research output: Contribution to journal › Article › peer-review

52 Scopus citations

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. The manufactured AM mold was used to fabricate 50 composite parts with no observed mold deformations.

Original language	English
Article number	101093
Journal	Additive Manufacturing
Volume	32
DOIs	https://doi.org/10.1016/j.addma.2020.101093
State	Published - Mar 2020

Funding

This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan ( http://energy.gov/downloads/doe-public-access-plan ). Research sponsored by the U.S. Department of Energy , Office of Energy Efficiency and Renewable Energy , Advanced Manufacturing Office , under contract DE-AC05-00OR22725 with UT-Battelle, LLC.

Keywords

AM molds
MGAW
Metal Big Area Additive Manufacturing (MBAAM)
Robotic welding
Smart manufacturing

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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10.1016/j.addma.2020.101093

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title = "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. The manufactured AM mold was used to fabricate 50 composite parts with no observed mold deformations.",

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AB - 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. The manufactured AM mold was used to fabricate 50 composite parts with no observed mold deformations.

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Scaling Up metal additive manufacturing process to fabricate molds for composite manufacturing

Abstract

Funding

Keywords

UN SDGs

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