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By combining the two production processes of open die forging and selective laser melting, the disadvantages of each process can be circumvented. For this purpose, the respective method is only used in the segment of the part for which it is suitable. A basic body is conventionally forged and subsequently machined to produce a plane surface. On this surface, the functionally optimized contour is added by selective laser melting.
With this innovative production chain, for which Rosswag GmbH was awarded the German Resource Efficiency Award (Deutscher Rohstoffeffizienz-Preis 2016), a component is created which consists of one identically material charge and has been produced in a resource-saving manner. The loss of material is reduced, since the complex geometries aren’t produced with high costs and expenditure of time by machining. This also reduces the consumption of coolants and lubricants.
The remnants produced during sawing and forging can be used for the additive manufacturing process. For this purpose, they are converted into a fine-grained metal powder in an atomizing process. The so-called Atomizer has a melting crucible in which the metal scrap is heated above the melting point. The molten material is atomized from the crucible via a nozzle by means of an inert gas stream to a spray. Subsequently, the spray particles solidify in the drop tower. In a downstream process step, the particles are fractionated for a stable SLM process between 10 μm and 60 μm.
The forging-SLM-Hybrid produced in this way offers a possibility to equip even large-volume parts with features which can only be realized by the additive manufacturing process. Due to the optimum grain structure profile, the forged component area has excellent mechanical-technological properties, especially with regard to the fatigue strength. The complex segments of the part are then manufactured in such a way that an added value results which could not be achieved by conventional production processes.
The hybrid production process is therefore the ideal approach to meet safety requirements and still achieve a functional optimization of the component. Lightweight components in particular must be designed in such a way that the requirements can be met by the use of additive manufacturing technology.
- Blades with inner channels (impossible to machine)
- Improved cost efficiency thanks to hybrid process approach
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