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Direct Metal Deposition

Direct Metal Deposition. Unit 91. Objectives. Describe DMD and be able to compare it with conventional rapid prototyping processes Explain what is meant by “The Big Three of Manufacturing” Discuss how the DMD process is used in various industrial applications. Direct Metal Deposition (DMD).

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Direct Metal Deposition

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  1. Direct Metal Deposition Unit 91

  2. Objectives • Describe DMD and be able to compare it with conventional rapid prototyping processes • Explain what is meant by “The Big Three of Manufacturing” • Discuss how the DMD process is used in various industrial applications

  3. Direct Metal Deposition (DMD) • Form of rapid tooling • Makes parts/molds from metal powder, melted by laser to computer-aided design of part, and then solidified • Rate of solidification dependent on heat-affected zone of laser and metallurgical properties of powder • Allows production of molds/dies in end material

  4. DMD Technology • Blending of five common technologies • Lasers • Computer-aided design (CAD) • Computer-aided manufacturing (CAM) • Sensors • Powder metallurgy

  5. DMD Process • Focuses CO2 laser beam onto flat tool-steel workpiece to create molten pool of metal • Small stream powdered tool steel injected into melt pool • Move laser beam back and forth (CNC control) tracing out pattern (CAD design) • Solid metal part built, line by line, one layer at a time • No material waste

  6. DMD • Creates consistent, fine microstructures that yield superior quality and tool strength • Allows creation of mixture of graded metallic compositions that have never been available • Provides closer tolerances • Lower tooling costs • Improved productivity

  7. From CAD to Steel • Customer posts CAD files • Engineers download and edit CAD files • Updated CAD model sliced, toolpaths created • Data post-processed and embeds laser and powder commands • Information downloaded to 3-axis machine • DMD process • Hard faces applied within argon filled box

  8. DMD Materials • Variety of metal powders and metal matrix composite materials • Tool-steel alloys • Stainless steel • Copper • Stellite alloys • Inconel • Tungsten carbide • Titanium diboride • Fast solidification rate results in very-fine-grain part microstructure

  9. Big Three of Manufacturing • Speed • Faster product to market • Economy • Lower tooling costs due to factors including reduction of labor and capital equipment costs • Quality • Parts produced are generally .001 in. oversized • Quick clean-up and ready for use

  10. DMD Applications • Die repair and refurbishment • Thermal management • Creation of thermal model to locate hot spots • Direct metal prototypes instead of plastic models • Surface modification and coatings • Aerospace and aircraft component repair

  11. From Prototype to Production • Time saved - deposition begins when CAD file ready • First-stage tooling (create prototype) • Design change flexibility • Material added to tooling without interface boundary • Suitability for complex designs • Work same without regard for size or complexity

  12. Overview • DMD process among most promising metalworking advances in decades • Benefits directly impact manufacturers' bottom line • Reduce time to market • Die repair and refurbishment • Direct metal prototyping • Thermal management • Strength improvements • Reduce environmental waste

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