Tailor-made functional composite components using additive manufacturing and hot isostatic pressing

Powder Metallurgy, vol. 64, pp. 295–307

Abstract

The combination of Additive Manufacturing (AM) and Hot Isostatic Pressing (HIP) offers great potential for industrial applications. Skilfully connecting AM and HIP creates a manufacturing process that unites the advantages of the two approaches. We demonstrate a production route for composite components by combining AM and HIP: a HIP capsule made of corrosion resistant steel is additively manufactured using Powder Bed Fusion with Laser Beam (LPBF). Before LPBF, the distortion and shrinkage of the capsule due to HIP is compensated by optimising the capsule’s geometry using Finite Element (FE) simulation of the HIP process. The capsule is filled with steel powder and manufactured by a conventional powder HIP. After HIP, the capsule remains as an outer layer on the component, so that a functional net-shape composite component is produced. Subsequent investigations show that a complex extruder screw segment can be successfully produced with a geometrical deviation smaller than 1.5%.

Authors 7

1. Sebastian Riehm Aachen Institute for Materials Applications in Mechanical Engineering

   RWTH Aachen University

   Affiliation as printed

   Institute for Materials Applications in Mechanical Engineering (IWM), RWTH Aachen, Aachen, Germany

2. Vera Friederici

   Leibniz-Institut für Werkstofforientierte Technologien - IWT · Fraunhofer Institute for Manufacturing Technology and Advanced Materials

   Affiliation as printed

   Fraunhofer Institute for Manufacturing Technology and Advanced Materials (IFAM), Bremen, Germany

   Leibniz Institute for Materials Engineering – IWT, Bremen, Germany

3. Sandra Wieland

   Fraunhofer Institute for Manufacturing Technology and Advanced Materials

   Affiliation as printed

   Fraunhofer Institute for Manufacturing Technology and Advanced Materials (IFAM), Bremen, Germany

4. Yuanbin Deng corresponding Aachen Institute for Materials Applications in Mechanical Engineering

   RWTH Aachen University

   Affiliation as printed

   Institute for Materials Applications in Mechanical Engineering (IWM), RWTH Aachen, Aachen, Germany

5. Simone Herzog Aachen Institute for Materials Applications in Mechanical Engineering

   RWTH Aachen University

   Affiliation as printed

   Institute for Materials Applications in Mechanical Engineering (IWM), RWTH Aachen, Aachen, Germany

6. Anke Kaletsch Aachen Institute for Materials Applications in Mechanical Engineering

   RWTH Aachen University

   Affiliation as printed

   Institute for Materials Applications in Mechanical Engineering (IWM), RWTH Aachen, Aachen, Germany

7. Christoph Broeckmann Aachen Institute for Materials Applications in Mechanical Engineering

   RWTH Aachen University

   Affiliation as printed

   Institute for Materials Applications in Mechanical Engineering (IWM), RWTH Aachen, Aachen, Germany