Study
Final ProductionHigh ImpactStrong effect

Laser Metal Deposition extends hot forging die lifespan by enhancing wear resistance

Applying a Stellite 21® alloy coating via Laser Metal Deposition to hot forging dies significantly improves their resistance to both adhesive and abrasive wear compared to standard H13 tool steel.

Journal of remanufacturing · 2018

01

Key Findings

  • 01LMD-p Stellite 21® additive layers demonstrated superior performance in both adhesive and abrasive wear conditions compared to standard H13 tool steel dies.
  • 02The LMD-p process is suitable for applying hard-facing alloys to complex tool geometries.
02

Application

Design takeaway

Consider additive manufacturing processes like LMD-p for repairing or enhancing tooling that experiences significant wear, particularly in forging applications, by using wear-resistant alloys like Stellite 21®.

How to apply

When designing or specifying tooling for high-wear environments, investigate the potential for additive manufacturing to apply specialized wear-resistant coatings to extend component life and reduce replacement costs.

Project actions

  • 01When researching materials, look for alloys known for high wear resistance.
  • 02Explore additive manufacturing techniques as a method for repairing or enhancing existing components rather than always designing new ones.
03

Method & Evidence

AimTo evaluate the effectiveness of Laser Metal Deposition with powder (LMD-p) using Stellite 21® for remanufacturing hot forging tools and dies by assessing their performance against standard H13 tool steel under industrial wear conditions.
MethodExperimental comparison
ProcedureStandard H13 tool steel dies were coated with Stellite 21® using LMD-p. The coated dies were then machined to their final geometry. These remanufactured dies were subjected to hot forging under controlled industrial conditions on a screw press, and their adhesive and abrasive wear characteristics were evaluated and compared to uncoated benchmark dies.
ContextHot forging industry, tool and die manufacturing

Variables

IVApplication of Stellite 21® coating via LMD-p
DVAdhesive and abrasive wear resistance of hot forging dies
CVHot forging conditions, screw press type, H13 tool steel standard, Schuler screw press (160 kJ)
04

Strengths & Limitations

Strengths

  • +Utilizes industrial-scale testing equipment for realistic wear evaluation.
  • +Employs established metrology standards to ensure data reliability and reproducibility.

Limitations

The cost and accessibility of specialized equipment like laser metal deposition systems might be a barrier for some design projects.

Reliability & validity

The study's use of industrial-scale testing and standardized metrology methods contributes to its reliability and validity. However, the specific conditions and materials used may limit generalizability.

Think critically

While LMD-p shows promise, what are the potential drawbacks or limitations of this technology in terms of cost, scalability, and the environmental impact of the process itself?

05

Design Principles

"Utilize additive manufacturing for targeted material deposition to enhance the wear resistance and extend the service life of critical components."

This research offers a practical method for extending the operational life of critical tooling in high-wear manufacturing processes. By leveraging additive manufacturing for repair and enhancement, designers can reduce material waste and the frequency of tool replacement, leading to cost savings and improved production efficiency.

06

What This Means for Your Design

Using a special welding technique with a hard metal powder can make forging tools last much longer by making them tougher against wear and tear.

How to use in your project

  • 1.Reference this study when discussing material selection for components subjected to wear, or when exploring additive manufacturing as a design solution for durability.
07

Add to My Project

08

Quick Cite

(2018). Remanufacture of hot forging tools and dies using laser metal deposition with powder and a hard-facing alloy Stellite 21®. Journal of remanufacturing. https://doi.org/10.1007/s13243-018-0063-9 Retrieved from https://designdex.org/study/e5b7e870-3656-4ba1-affc-fb23a403d36a/laser-metal-deposition-extends-hot-forging-die-lifespan-by-enhancing-wear-resistance

Paragraph starter

Research indicates that additive manufacturing processes, such as Laser Metal Deposition with powder (LMD-p), can significantly enhance the durability of tooling. For instance, applying a Stellite 21® alloy coating to hot forging dies has been shown to improve resistance to both adhesive and abrasive wear, extending their operational lifespan compared to standard materials.

09

Source

Journal of remanufacturing

Remanufacture of hot forging tools and dies using laser metal deposition with powder and a hard-facing alloy Stellite 21®

journal · 2018

View source

Questions about this research

What does the research say about laser metal deposition extends hot forging die lifespan by enhancing wear resistance?
Consider additive manufacturing processes like LMD-p for repairing or enhancing tooling that experiences significant wear, particularly in forging applications, by using wear-resistant alloys like Stellite 21®. Evidence: Journal of remanufacturing (2018).
Why does "Laser Metal Deposition extends hot forging die lifespan by enhancing wear resistance" matter for design?
This research offers a practical method for extending the operational life of critical tooling in high-wear manufacturing processes. By leveraging additive manufacturing for repair and enhancement, designers can reduce material waste and the frequency of tool replacement, leading to cost savings and improved production efficiency.
How can designers apply this research?
Consider additive manufacturing processes like LMD-p for repairing or enhancing tooling that experiences significant wear, particularly in forging applications, by using wear-resistant alloys like Stellite 21®.
What were the main findings?
LMD-p Stellite 21® additive layers demonstrated superior performance in both adhesive and abrasive wear conditions compared to standard H13 tool steel dies.. The LMD-p process is suitable for applying hard-facing alloys to complex tool geometries.
What research method was used?
Experimental comparison.
How strong is the evidence?
Evidence strength is rated Strong effect, based on a 2018 journal from Journal of remanufacturing.
What should I do differently in my next project?
When designing or specifying tooling for high-wear environments, investigate the potential for additive manufacturing to apply specialized wear-resistant coatings to extend component life and reduce replacement costs.
What are the limitations?
The study focused on a specific alloy (Stellite 21®) and a particular hot forging application; performance may vary with different materials, processes, or wear conditions.
Is there evidence that laser metal affects design outcomes?
Dies repaired with a laser-deposited Stellite 21® coating lasted longer and resisted wear better than standard dies. This research offers a practical method for extending the operational life of critical tooling in high-wear manufacturing processes. By leveraging additive manufacturing for repair and enhancement, desig Source: Journal of remanufacturing (2018).
Where does this metal deposition research apply?
Hot forging industry, tool and die manufacturing It sits within final production research on designdex.org.

Related research topics

laser metal design research · evidence on laser metal · does laser metal improve design outcomes · metal deposition studies for designers · laser metal and metal deposition findings · final production research evidence