Skip to main content
SpringerLink
Log in

The effect of scanning strategy on laser fusion of functionally graded H13/Cu materials

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

In recent years, research has been undertaken on manufacturing of functionally graded materials (FGM) using layered manufacturing technologies (LMT), also commonly known as rapid prototyping (RP), solid free-form fabrication (SFF) etc. The use of LMT to build complex FGM parts could meet optimum engineering design for various applications such as high performance die casting tools. In this context, H13 tool steel is considered a suitable material because of the high resistance to thermal fatigue and dimensional stability. Nevertheless, H13 with a low heat conduction coefficient is not thermally efficient for certain part geometries. With this in mind, the use of functionally graded techniques to disperse copper to specific regions/volumes of a H13 mould could lead to higher performance of the tool. The laser fusion of different proportions of Cu (0, 25 and 50% by weight) powder dispersed in H13 were analysed in this work. Additionally, different laser strategies were used to statistically analyse effects with respect to the composition of Cu. It was found that the refill strategy produces better results compared to all other scanning methods. The H13 with 25% Cu mix produced a homogeneous structure but cracks were observed along the cross section of the 25% Cu specimens. The pure H13 had a lower porosity with fine dendrite structures. The H13 with 50% Cu produced a non-homogeneous structure. This paper also discusses the microhardness tests results with respect to Cu composition and scanning strategy. Also, in order to identify the effect of powder composition layer on the subsequent layers and the cooling rate effect, samples were produced and analysed. One started with 100% H13 and ended with H13+50% Cu while the other started with H13+50% Cu and ended with 100% H13.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Wohlers T (2004) Wohlers Report 2004. Wohlers Associates, Inc., USA, ISBN 0975442902

  2. Suresh S, Mortensen A (1998) Fundamentals of functionally graded materials. Institute of Materials, London, ISBN 1-86125-063-0

  3. Norton RL (1996) Machine design: an integrated approach. Prentice-Hall, New Jersey, ISBN 0-13-555475-6

  4. Smith WF (1993) Structure and properties of engineering alloys, 2nd edn. McGraw-Hill, New York, ISBN 007591725

  5. Menges G, Mohren P (1993) How to make injection molds, 2nd edn. Hanser, Munich, Germany, ISBN 1569902828

  6. Su W (2002) Layered fabrication of tool steel and functionally graded materials with a Nd:YAG pulsed laser. PhD Thesis, Loughborough University, Loughborough, UK

  7. Beal VE, Erasenthiran P, Hopkinson N, Dickens P, Ahrens, CH (2004) Fabrication of x-graded H13 and Cu powder mix using high power pulsed Nd:YAG laser. In: Proceedings of Solid Freeform Fabrication Symposium, 2–4 August, Austin, TX, USA

  8. Storch S, Nelessen D, Shaefer G, Reiter R (2003) Selective laser sintering: qualifying analysis of metal based powder systems for automotive applications. Rapid Prototyping J 9(4):240–251

    Article  Google Scholar 

  9. Atwood C, Griffith LH, Schlienger E, Ensz M, Smugeresky J, Romero T, Greene D, Reckaway D (1998) Laser engineering net shaping (LENS™): a tool for direct fabrication of metal parts. In: Proceedings of ICALEO ‘98, 16–19 November 1998, Orlando, FL, USA, pp E1–E7

  10. Ensz MT, Griffith ML, Reckaway DE (2002) Critical issues for functionally graded material deposition by Laser Engineered Net Shaping (LENS™). In: Proceedings of the 2002 International Conference on Metal Powder Deposition for Rapid Manufacturing, 8–10 April, San Antonio, TX, USA, pp 195–202

  11. Lu L, Fuh J, Wong YS (2001) Laser-induced materials and processes for rapid prototyping. Kluwer Academic, Norwell, ISBN 0792374002

  12. Morgan R, Sutcliffe CJ, O’Neill W (2001) Experimental investigation of nanosecond pulsed Nd:YAG laser re-melted re-placed powder beds. Rapid Prototyping J 7(3):159–172

    Article  Google Scholar 

  13. Pogson SR, Fox P, Sutcliffe CJ, O’Neill W (2003) The production of copper parts using DMLR. Rapid Prototyping J 9(5):334–343

    Article  Google Scholar 

  14. Leong CC, Lu L, Fuh JYH, Wong YS (2002) In-situ formation of copper matrix composites by laser sintering. Mater Sci Eng A 338:81–88

    Google Scholar 

  15. Abe F, Osakada K, Shiomi M, Uematsu K, Matsumoto M (2001) The manufacturing of hard tools from metallic powders by selective laser sintering. J Mater Process Technol 111:210–213

    Article  Google Scholar 

  16. Kumar P, Santosa JK, Beck E, Das S (2004) Direct-write deposition of fine powders through miniature hopper-nozzles fos multi-material solid freeform fabrication. Rapid Prototyping J 10(1):14–23

    Article  MATH  Google Scholar 

  17. Yang S, Evans JRG (2004) Acoustic control of powder dispensing in open tubes. Powder Technol 139:55–60

    Article  Google Scholar 

  18. Cho W, Sachs EM, Patrikalakis NM (2001) Solid freeform fabrication with local composition Control. In: Newsletter Published by Rapid Prototyping Association of the Society of Manufacturing Engineers 7(2):1–5

  19. German RM (1994) Power metallurgy science, 2nd edn. MPIF, New Jersey, USA, ISBN 1-878954-42-3

  20. OSPREY Metal Powders. Microfine Powder-H13 Datasheets. http://www.ospreymetals.co.uk. Accessed on 15 November 2003

  21. UTHSCSA Website, The University of Texas Health Science Center at San Antonio, ImageTool Version 3.0, http://ddsdx.uthscsa.edu/dig/itdesc.html. Accessed on January 2004

  22. Brooks J, Robino C, Headley S, Griffith M (1999) Microstructure and property optimization of LENS® deposited H13 tool steel. In: Proceedings of Solid Freeform Fabrication Symposium, 9–11 August, Austin, TX, USA, pp 375–382

  23. MATWEB Material Property Data. AISI Type H13 Hot Work Tool Steel, air or oil quenched from 995–1025°C http://www.matweb.com. Accessed on 20 March 2004

Download references

Author information

Authors and Affiliations

  1. Departamento de Engenharia Mecânica, Campus Universitário, Universidade Federal de Santa Catarina, POSMEC, Caixa Postal 476, Trindade, Florianópolis, SC, 88040900, Brazil

    V. E. Beal & C. H. Ahrens

  2. Rapid Manufacturing Research Group, Wolfson School of Mechanical and Manufacturing Engineering, Loughborough University, Loughborough, LE11 3TU, UK

    P. Erasenthiran, N. Hopkinson & P. Dickens

Authors
  1. V. E. Beal
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. P. Erasenthiran
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. N. Hopkinson
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. P. Dickens
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. C. H. Ahrens
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to P. Erasenthiran.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Beal, V.E., Erasenthiran, P., Hopkinson, N. et al. The effect of scanning strategy on laser fusion of functionally graded H13/Cu materials. Int J Adv Manuf Technol 30, 844–852 (2006). https://doi.org/10.1007/s00170-005-0130-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-005-0130-x

Keywords

Search

Navigation