Material design for additive manufacturing of industrial tools

Purpose and goal

The project is about implementation of simulation tools to develop materials with optimised properties, specifically adapted for additive manufacturing. The focus is tool material for harsh operating conditions, where increased service life will promote cost efficiency and competitiveness. Four alloys have been optimized to meet the demands from the tooling applications. The performance has been demonstrated and the results are promising. After additional testing, implementation in pilot scale production could be possible for some applications after the project.

Expected results and effects

The goal of the project to develop generic methods for development of AM materials and to demonstrate the performance of optimized AM alloys in relevant industrial tooling applications has been achieved. The effect will be shorter lead time for developing new material grades for AM but also the possibility to develop customized materials for specific applications. Therefore, the number of available AM alloys will increase and hence also the number of possible AM applications which will raise the industrial acceptance for AM.

Planned approach and implementation

The project has delivered validated methods for implementation of integrated calculation tools to enable development of unique and customised AM materials. Four new alloys have been optimized and manufactured by atomization of powder, additive manufacturing, and heat treatments. After validation of the mechanical properties, the performance has been demonstrated in specific applications including machining, mine drilling and extrusion of rubber. Close collaboration between industry and research partners has been the basis for achieving this.