Integration of Metal Additive Manufacturing in Precision Casting Foundries

Important results from the project

The objective of this project is to introduce Ventana Hackås AB to the possibility of integrating metal additive manufacturing (AM) in their production. Focus is placed on selective laser melting (SLM) technology for the production of aluminium parts. This technology has commonalities with precision casting and can complement a casting foundry in a number of ways. Firstly, SLM is highly cost-efficient for low series production of complex parts. Secondly, commercially available aluminium alloys for SLM processing are similar to those that were originally invented for casting.

Expected long term effects

Ventana Hackås produces aluminium parts by precision casting with plaster moulds. However, for certain specific parts, Ventana Hackås has not been able to fulfil the requirements of their customers either with respect to properties or with respect to price. One important driving force for this project was to investigate the capabilities of SLM for manufacturing such components. The results show that by adopting the SLM Ventana Hackås can expand their product portfolio with parts which are typically not suitable for precision casting. This can bring new business opportunities.

Approach and implementation

Ventana Hackås proposed a component for manufacturing by SLM. The mechanical and surface finish requirements for the component were defined. RISE IVF manufactured the component by SLM. To reduce weight, an aluminium alloy was used (currently the part is manufactured from stainless steel). The part was printed in several orientations. The distortion was simulated to find the best orientation and support structure type. The dimensional accuracy and surface roughness were also measured. It was found that the dimensional accuracy of the parts depends on the printing orientation.