Int J Adv Manuf Technol (2008) 39:898904 DOI 10.

1007/s00170-007-1281-8

ORIGINAL ARTICLE

Complex cast parts with rapid tooling: rapid manufacturing point of view
E. Pessard & P. Mognol & J. Y. Hascot & C. Gerometta

Received: 26 June 2007 / Accepted: 9 October 2007 / Published online: 7 November 2007 # Springer-Verlag London Limited 2007

Abstract Rapid manufacturing techniques are typically either material addition or material subtraction processes. Direct metal laser sintering (DMLS) is a material addition process that enables the rapid creation of complex parts via laser sintering (or electron beam melting) whereby layers of powder are deposited and then partially or totally melted using a laser. This technique is directly challenging other more rapid, but subtractive manufacturing processes like high-speed milling (HSM) and electro-erosion. In terms of machining, the capacity of rapid tooling to quickly manufacture complex shapes, like conformal cooling channels, is an advantage (Boillat in J Phys IV 12(Pr 11):2738, 2002, Au in Int J Adv Manuf Technol 34:496515, 2007). On the other hand, the dimensional accuracy of this process is definitely lower than that obtained using HSM. To our knowledge, no systematic study of the dimensional capacities of this process has yet been carried out. In this article, through the geometrical study of the quality of the obtained parts, the

capability of this process is studied and verified with respect to the required constraints of the die casting method. Keywords Rapid tooling . DMLS . Die casting . Prototyping . Laser sintering . Dimensional accuracy

1 Background and literature review Metal parts made via a laser sintering process are becoming more and more popular in rapid manufacturing. Thus, many studies have been carried out in order to characterise these parts. Khaing [3] concluded that the direct metal laser sintering (DMLS) process was able to produce 3D metal parts with very fine details. But, the sintered parts were relatively soft, rough and porous. A CMM machine was used to measure the dimensional accuracy of two parts (one with an epoxy infiltration and one without). The measured dimensional errors ranged from 0.003 mm to 0.34 mm depending on the feature considered (i.e., length, diameter, etc). Khaing [3] proposed to work on the accuracy of the LASER optical unit in order to improve the part quality and accuracy. This work is very interesting, but only one part was measured in order to determine the accuracy of each process. Wang [4] studied the density, the porosity and the surface roughness of an iron based, laser sintered material used in the DMLS process. Concerning the measurement of surface roughness, he concluded that the building direction has a coarser topography (Ra 18.2 m) than the surface parallel to the building direction (Ra 12.6 m). This raises questions about the dimensional accuracy in the building direction. To improve the surface porosity of sintered metal parts, Panjan [5] suggested the addition of a protective coating with an appropriate physical vapour deposition process. The

E. Pessard (*) : C. Gerometta LPMI, EA 1427, ENSAM, 2 Boulevard du Ronceray, 49035 Angers, France e-mail: etienne.pessard@angers.ensam.fr C. Gerometta e-mail: christian.gerometta@angers.ensam.fr E. Pessard : P. Mognol : J. Y. Hascot IRCCYN, UMR CNRS 6597, 1 rue de la No, Nantes, France P. Mognol e-mail: pascal.mognol@bretagne.ensam-cachan.fr J. Y. Hascot e-mail: jean-yves.hascoet@irccyn.ec-nantes.fr

Int J Adv Manuf Technol (2008) 39:898904

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Fig. 1 The principal of sintering

results show that a duplex electroless nickel-phosphorus (ENiP) / PVD hard coating double layer improves the surface quality of DMLS parts with regard to their mechanical strength, roughness and wear resistance if the thickness of the ENiP coat is greater than 10 m. Similarly, Tay [6] suggested using EN plating followed by semi-bright nickel electroplating. This technique reduces the plating time significantly. However, the main problem associated with these methods is the dimensional accuracy. In particular, does the coating have a constant thickness and what is the consequence on the dimensional accuracy of the metal parts? Tay [5] concluded that semi-bright plating is inappropriate where dimensional accuracy is a primary concern. In spite of this, Ferreira [7] and the other researchers affirm that DMLS is the most accurate technology for the direct manufacturing of tooling. Krut [8] has examined different selective laser sintering/ selective laser melting (SLS/SLM) processes with regard to the condition that are important for manufacturing, such as dimensional accuracy, material and mechanical properties, speed and reliability. A benchmark model was developed to test these conditions and five SLS/SLM machines were used to manufacture the benchmark model. One benchmark model was manufactured per SLS/SLM process. A dimensional analysis was performed to measure the process accuracy. It was concluded that the accuracy of the DMLS

Fig. 3 The initial test part

process is good. It is important, however, to note that only one part was manufactured for each process. Hence, these results give a good idea of the accuracy but are not conclusive from a statistical point of view. The research undertaken in our laboratory, in this field, follows the work concerning the competition between material additive and material subtractive rapid manufacturing processes [911]. In this paper, the dimensional accuracy survey is based on 14 parts, manufactured using the same process (i.e., the DMLS process by EOS). Hence, by assuming that the dimensional error distribution is Gaussian, it is possible to determine the mean and standard deviation to quantify the dimensional accuracy of the process.

2 Design and production of a test part The test parts were produced using a rapid prototyping machine (250 Xtend from the company EOS).

Fig. 2 The DMLS process

900 Fig. 4 a) The mould, b) The pattern cavity

Int J Adv Manuf Technol (2008) 39:898904

The rapid manufacturing of parts by the DMLS process requires the use of a powder, which is composed of two types of particles. One type has a low melting point, and the other a high melting point. The high melting point particles generate a solid matrix while the particles with the low melting point bind the matrix after being melted by the laser energy input (Fig. 1). A component is manufactured, layer by layer along the Z axis. The layer of powder is deposited via a scraper moving in the X-Y plane (Fig. 2). In order to create a test part for the die casting process, the main characteristics of components made via die casting and the constraints applied to the rapid process were listed and a test part was proposed (Fig. 3). A component with the following characteristics was desired: Thin rectangular sections with different thicknesses and orientations

Hollow cylinders with different internal and external diameters A shape tailored to die casting (fillet radii, round off, relief, etc)

The quality of the test parts obtained via DMLS depends on their orientation relative to the fabrication plate. This is why identical forms with different orientations with respect to the axis of the machine were used. Next the tooling was designed; the mould and the pattern cavity for this part are shown in Fig. 4. Simulation of the filling of the pattern cavity was carried out with the commercial finite difference casting package PAM QUICKCAST. At the end of this step, the design of the mould and the design of the obtained part by metal injection were thus validated. In order to evaluate the dimensional accuracy of the DMLS process for these typical features (interior and exterior thin feature), it was decided that one half of the

Fig. 5 The final test part design

Int J Adv Manuf Technol (2008) 39:898904 Table 1 Mechanical characteristics Powder Youngs Yield Fracture Brinell Max. type modulus E strength strength hardness operating (GPa) (MPa) (MPa) (HB) temperature(C) DM20 DS20 80 130 400 600 700 1000 110 220 400 800

901

It is possible to use two types of powder: DM20 (a copper based powder direct metal) and DS 20 (a steel based powder direst steel). The mechanical characteristics of the material created via this process are given in Table 1. For the tooling application, the powder DS 20 was used. Shot-peening of the part surface is often recommended in order to improve the surface quality and to increase the surface hardness. The influence of this post treatment on the dimensional accuracy will be discussed below.

test part would be indicative of the mould and the other half indicative of the part. 14 parts were manufactured via metal powder sintering, so as to have a sufficiently representative batch of parts in which to study the geometrical accuracy (Fig. 5).

3 Various tests Before manufacturing the test parts, the rapid prototyping machine was careful adjusted and calibrated using a

Fig. 6 a) A test part showing the measured dimensions, b) Positioning of the parts on the plate

Fig. 7 Deviation from the nominal cylindrical dimension as a function of the distance from the centre of the platform

902 Table 2 Average oversize Cylindrical values Average oversize hollow cylinder (42 measurements) Average oversize solid cylinder (56 measurements) 0.279 mm 0.185 mm

Int J Adv Manuf Technol (2008) 39:898904

sintering. The statistical aspect of the study is emphasised in order to determine the dimensional accuracy of the process. Another objective of this work is to highlight the critical steps in the production of a component via DMLS. 4.1 Test parts before shot peening Measurements of the different cylindrical dimensions show that the dimensional error strongly depends on the distance from the centre of the platform (see Fig. 7). Note that the hollow cylinders have a greater machining allowance than the solid cylinders. Figure 7 allows the definition of a critical distance (d= 100 mm) from the centre of the platform, at which the dimensional error rapidly increases (see Fig. 7 and Table 2). Concerning these measured cylindrical values, it can be seen that very similar results are found on both platforms (see Fig. 8). Figure 8b shows that the process is repeatable on both platforms and more precisely that the dimensional errors are repeatable. When setting up the rapid prototyping machine a relatively small calibration piece is used. Consequently the parameters are optimised for a given position on the platform (i.e., the position of the calibration piece). It is, therefore, normal that the dimensional accuracy is highest for the features manufactured at this location. Similar dimensional errors were also observed for the thin wall sections and grooves. Table 3 summarises the results of the measurements before shot peening. It can be seen that each type of geometrical feature is characterised by a standard deviation of the same order of magnitude as that for the cylinders. The machining allowance added to the final dimensions is theoretically constant but in practice it strongly depends on the geometry of the feature. The rapid prototyping machine therefore has a weakness in this area. It is possible to adjust the machine to produce, with precision, a certain type of geometric feature (e.g., a hollow cylinder) by modifying process parameters.

calibration part proposed by EOS. This includes the following: Shrinkage coefficients (Rx and Ry): The dimensions of the sintered part must be larger than the dimensions of the finished part as the passage of the powder from a liquid state to a solid state causes shrinkage. This shrinkage depends on the direction of sintering. There are 2 shrinkage parameters Rx and Ry which must be identified and are approximately 0.1% shrinkage. Laser beam (b0): During the sintering process the position of the centre of the laser beam is controlled. It is thus necessary to specify the size of the laser beam (b0=0.21 mm). The shot-peening coefficient (fx): If shot-peening is carried out on the finished parts using small ceramic or steel balls, the dimensions of the part will be modified. It is, thus, necessary to correct the thickness using a shot-peening coefficient, Fx=0.06 mm

The 14 test parts were then produced seven at a time on a platform as shown in Fig. 6b. A CMM was then used to check the dimensional accuracy of the parts. The measured dimensions are shown in the Fig. 6. Each dimension was measured before and after shot peening. 4 Results The initial aim of this section is to determine the dimensional characteristics of the batch of 14 test parts created by laser

Fig. 8 a) Position of the test parts on the platform, b) Cylindrical dimension as a function of their position

Int J Adv Manuf Technol (2008) 39:898904 Table 3 Summary of measurements before shot peening Standard deviation =0.04 mm =0.03 mm =0.03 mm =0.04 mm 4 Standard deviation 4 =0.16 mm 4 =0.12 mm 4 =0.12 mm 4 =0.16 mm average machining allowance m=0.28 mm m=0.18 mm m=0.20 mm m=0.24 mm Hollow cylinders (42 measurements) Solid cylinders (56 measurements) Wall sections (82 measurements) Grooves (67 measurements) Table 5 Results of measurements after shot peening Standard deviation 4 standard deviations

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Average difference from the nominal value

Hollow cylinders (42 measurements) Solid cylinders (56 measurements) Wall sections (82 measurements) Grooves (67 measurements)

=0.05 mm 4 =0.20 mm m=0.14 mm =0.04 mm 4 =0.16 mm m=0.05 mm =0.03 mm 4 =0.12 mm m=0.01 mm =0.04 mm 4 =0.16 mm m=0.02 mm

However, in order to manufacture a component with a more varied geometry, it is expected that difficulties will be experienced and that the dimensional error will be higher. 4.2 After shot peening To improve the surface quality and to increase the surface hardness, shot-peening of the test parts was undertaken. The summary of the measurements made after this process are shown in Table 4. It is observed that the precision as well as the reduction of thickness (due to shot-peening) depend on the type of geometry, indeed the standard deviation of the thickness removed by shot-peening is twice as higher for complex geometries (cylinders) than for simple geometries (wall sections and grooves). 4.3 Finished parts Table 5 summarises the measurements taken on the finished parts. It can be seen that the standard deviation is rather

high and that the average difference from the nominal value depends on the type of geometric feature.

5 Discussion The geometrical accuracy of the rapid prototyping machine used in this work is approximately 0.2 mm (or approx. four standard deviations). This corresponds to a workpiece tolerance of approximately 0.1 mm, with 50% of this inaccuracy coming from the sintering machine and 50% coming from the shot-peening. It is possible to optimize the parameters of the rapid prototyping machine to improve the results obtained but different adjustments are needed depending on the geometric features manufactured (i.e., cylinders, wall sections, etc). A compromise must, therefore, be used when a component has many different geometric features. In addition the various adjustments of the machine parameters are local. That is, the calibration of the machine is optimised for a relatively small zone of the possible work area. Consequently a large component will have greater dimensional errors than a smaller one.

Table 4 Summary of measurements after shot peening Standard deviation =0.04 mm =0.04 mm =0.04 mm =0.02 mm =0.02 mm =0.02 mm 4 Standard deviation 4 =0.16 mm 4 =0.16 mm 4 =0.16 mm 4 =0.06 mm 4 =0.06 mm 4 =0.06 mm Average machining allowance m=0.14 mm m=0.14 mm m=0.14 mm m=0.11 mm m=0.11 mm m=0.11 mm

6 Conclusion In conclusion, this work makes it possible to evaluate the suitability of the DMLS process for the manufacturing of moulds for die casting, in term of dimensional accuracy, while at the same time highlights certain critical points. These include a change in the precision of the DMLS process depending on the location in the workspace and the decrease in dimensional accuracy due to shot-peening. The dimensional specifications in the casting industry for moulds are strict with typical tolerances being the order of 0.05 mm. It is, thus, necessary to further improve the process. This includes improving the shot-peening process.

Hollow cylinders (42 measurements) Solid cylinders (56 measurements) All cylinders (98 measurements) Wall sections (82 measurements) Grooves (67 measurements) Walls and grooves (149 measurements)

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Int J Adv Manuf Technol (2008) 39:898904 5. Panjan P, Dolinsek S, Dolinsek M, Cekada M, Skarabot M (2005) Improvement of laser sintered tools with PVD coatings. Surf Coat Technol 200:712716 6. Tay FEH, Haider EA (2002) Laser sintered rapid tools with improved surface finish and strength using plating technology. J Mater Process Technol 121:318322 7. Ferreira JC (2004) Rapid tooling of die DMLS inserts for shotsqueeze moulding (DISA) system. J Mater Process Technol 155 156:11111117 8. Kruth J-P, Vandenbroucke B, Vaerenbergh JV, Mercelis P (2005) Benchmarking of different SLS/SLM processes as rapid manufacturing techniques, Int. Conf. Polymers and Moulds Innovations, Gent, Belgium, April 2023, 2005 9. Mognol P, Jegou L, Rivette M, Furet B (2006) EDM, HSC and DMLS: A method to use efficaciously these process in Hybrid Rapid Tooling. Int J Adv Manuf Technol 29(12):3540 10. Mognol P, Rivette M, Jegou L, Lesprier T (2007) A first approach to choose between HSM, EDM and DMLS processes in Hybrid Rapid Tooling. Rapid Prototyping J 13(1):716 11. Rivette M, Hascot JY, Mognol P (2007) A based graph methodology for hybrid rapid design. J Eng Manuf 221(4): 685697

Future work will include the creation of the tooling via DMLS and subsequent die casting of the test pieces. It will then be possible to quantify the dimensional dispersion due to the complete process (i.e., creation of the tooling, and the manufacturing of the test pieces via die casting). References
1. Boillat E, Glardon R, Paraschivescu D (2002) Optimisation Thermique de moules dinjection construits par des processus gnratifs. J Phys IV, 12(Pr 11):2738 2. Au KM, Yu KM (2007) A scaffolding architecture for conformal cooling design in rapid plastic injection moulding. Int J Adv Manuf Technol 34:496515 3. Khaing MW, Fuh JYH, Lu L (2001) Direct metal laser sintering for rapid tooling: processing and characterisation of EOS parts. J Mater Process Technol 113:269272 4. Wang Y, Bergstrom J, Burman C (2006) Characterization of an ironbased laser sintered material. J Mater Process Technol 172:7787