Invention Reference Number
This technology utilizes additive manufacturing (AM) to meet the need of improved tooling performance by integrating variable thermal conductivity material by changing the alloy ratio of copper to steel within a mold component while improving the ease of manufacturability. Copper has up to 10 times the thermal conductivity of many steels, so alloying copper with steel utilizing the AM process enables the precise deposition location of the alloy with the desired thermal conductivity and hardness. These alloys will then be used for the manufacture of fluid channels and veins in a tool for cooling or heating.
Description:
Additive manufacturing enables the incremental buildup of components with a variety of materials, and material deposition locations, including the mixing of discrete metals at the melt pool during the deposition process. Controlling alloy ratios of a mixture of copper and steels for the purpose of improved tool thermal performance and ease of deposition will further enable increased thermal performance while balancing a decrease in hardness. By directly depositing the copper and steel, the mixture ratio can be controlled and tailored within a monolithic tool. This 5-axis hybrid manufacturing technology is capable of printing and machining cooling or heating channels in a part that could not be realized through traditional manufacturing methods. By alloying copper with steel utilizing the AM process, including blown powder directed energy deposition, the precise deposition location of the alloy with the desired thermal conductivity and hardness is possible. These alloys will then be used for the manufacture of conformal fluid channels and conductive veins within a tool. The final working surface can then be cladded in an increased wear-resistant material, then machined to shape. Current tooling must perform with the materials and thermal properties that are limited by current manufacturing methods including gun drilled channels and pressed copper inserts.
Benefits
- Better performance
- Less cost, faster cycle times
- More efficient
- High performance and quality that current state-of-the-art manufacturing cannot achieve
Applications and Industries:
- Tooling industry
- Any industry seeking custom tooling needs
- Fusion energy
- Aerospace
Contact:
To learn more about this technology, email partnerships@ornl.gov or call 865-574-1051.
