Additive Manufacturing Powder for Die-Casting Dies with Oxide Coating
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Solution Overview
Problem
Existing die-casting die materials, such as tool steel SKD61, have limitations in forming complex water-cooling circuits and suffer from reduced thermal conductivity due to high silicon content, which affects cooling performance and machinability.
Innovation Solution
A powder for additive manufacturing with a specific composition (0.25<C<0.40, 0.001≤Si≤0.15, 0.30≤Mn≤0.45, 5.0≤Cr≤5.5, 1.0≤Mo≤1.5, 0.35≤V≤0.45, 0.01≤N≤0.05, 0.01≤O≤0.04, and optional elements) is used, which is coated with an oxide film to prevent aggregation and improve conveyance, allowing for the creation of non-linear cooling circuits with enhanced thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tool steel for hot working (e.g., SKD61) is used for die-casting die, then high durability against heat check is achieved, but thermal conductivity is reduced due to high silicon content (0.9 mass%)
Solution Approach 1:
The patent changes the chemical composition parameters of the steel material by reducing silicon content to 0.15 mass% or less and adjusting other elements (C: 0.25-0.40, Mn: 0.30-0.45, Cr: 5.0-5.5, Mo: 1.0-1.5, V: 0.35-0.45) to achieve both high durability against heat check and high thermal conductivity. This resolves the contradiction by optimizing the compositional parameters rather than using conventional high-silicon tool steel.
2Ease of manufacture
If water-cooling circuit is formed by cutting, then simple linear circuits can be produced, but complex three-dimensional cooling circuits cannot be formed
Solution Approach 1:
The patent replaces the mechanical cutting method with additive manufacturing technology. The water-cooling circuit is formed by selectively melting and solidifying metal powder layers according to a three-dimensional model, enabling complex non-linear cooling circuits to be created directly without mechanical cutting. This substitution of manufacturing method resolves the limitation of conventional cutting techniques.
3Adaptability or versatility
If metal powder is used for additive manufacturing, then complex three-dimensional shapes can be formed, but powder aggregation occurs making conveyance difficult
Solution Approach 1:
The patent optimizes the particle size parameters of the metal powder (average particle size: 10-50 μm, specific surface area: 0.1-1.0 m²/g) to prevent aggregation and improve conveyance. The controlled particle size distribution and surface characteristics enable smooth powder flow in the additive manufacturing process while maintaining the ability to form complex three-dimensional structures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The powder enables the production of die-casting die parts with improved thermal conductivity and reduced processing requirements, eliminating the need for quenching and preventing aggregation, while maintaining high machinability and heat resistance.
Implementation Method 1
the surface of the powder for additive manufacturing is coated with an oxide film
Implementation Method 2
irradiating the powder layer with an energy beam such as a laser beam or an electron beam to thereby locally melt and solidify the powder layer
Implementation Method 3
irradiating the powder layer with an energy beam such as a laser beam or an electron beam to thereby locally melt and solidify the powder layer
Implementation Method 4
a water-cooling circuit internally so that molten metal press-fitted into the die can be solidified in a short time
Data Source
AI summary
The present invention relates to a powder for additive manufacturing, having a composition consisting of, in mass%: 0.25<C<0.40, 0.001≤Si≤0.15, 0.30≤Mn≤0.45, 5.0≤Cr≤5.5, 1.0≤Mo≤1.5, 0.35≤V≤0.45, 0.01≤N≤0.05, 0.01≤O≤0.04, and optionally, P<0.10, Cu<0.20, Ni<0.20, A1<0.05, Zr<0.05, S<0.20, Pb<0.20, Bi<0.20, Nb<0.20, Ti<0.20, B<0.10, and Co<0.20, with the balance being Fe and unavoidable impurities, in which a surface of the powder for additive manufacturing is coated with an oxide film, and the oxide film has a thickness of 3 nm or more and 30 nm or less.