Laser Based Flexible Fabrication of Functionally Graded Mould Inserts

A CO₂ laser-based freeform fabrication process with emphasis on difficult-to-shape and functionally effective materials was investigated with regard to fabrication of dies and moulds. Square and circular moulds were built by use of a material additive process of layers of TiC and Ni-alloy composite. The effects of laser processing on the quality, microstructures, and hardness of the moulds were determined. Additionally, the mould performance was evaluated in die-casting, injection moulding, and in a thermal fatigue environment. The TiC core-Ni-alloy shell mould outperformed moulds made of hardened H13 die steel, 304 stainless steel, and TiC-coated stainless steel in withstanding stresses and in retaining dimensional stability at elevated temperatures.