Examining mechanical properties of profiles manufactured aluminium extrusion dies using powder bed fusion

• Published in: Measurement : journal of the International Measurement Confederation 2021-06, Vol.177, p.109266, Article 109266
• Main Author: Özsoy, Koray
• Format: Article
• Language: English
• Subjects: Additive manufacturing; Aluminum base alloys; Die; Direct metal laser sintering; Extrudability; Extruders; Extrusion; Extrusion dies; Hardness tests; Hot work tool steels; Hot working; Intermetallic compounds; Laser sintering; Magnesium compounds; Maraging steels; Mechanical properties; Metal silicides; Microscopy; Microstructure; Optical microscopes; Powder bed fusion; Powder beds; Sintering (powder metallurgy); Surface roughness
• ISSN: 0263-2241; 1873-412X
• DOI: 10.1016/j.measurement.2021.109266

•Direct metal sintering process (DMLS) of Maraging steel (MS1) was performed.•The effect of additive manufacturing on the mechanical performance of AA 6063 profiles was assessed.•SEM was used to study the morphology of AA 6063 profiles surfaces.•Microstructure and mechanical properties were related to the Mg2Si content.•AA 6063 profiles obtained high quality and a good surface roughness at DMLS process. The present study investigated the effect of the mechanical properties and the extrusion die manufacturing of AA 6063 alloy on the surface appearance of Eloxal extrusions. The aim of this study was to benefit from the novel manufacturing freedom of powder bed fusion (PDF) in order to change the existing design concept of extrusion dies and solve the restrictions in die manufacturing. In this study, the designed aluminium extrusion dies were manufactured both by the traditional method using DIN 1.2344 hot-work tool steel and by a direct metal laser sintering (DMLS) process using EOS© maraging steel material. In the field experiments of the solid die a 1460 US ton extrusion press was used. Tensile, hardness tests, and surface roughness values were nominated to specify the mechanical properties of the AA 6063 alloy profiles. The microstructure of the aliminium profiles was analysed using both an optical microscope and a scanning electron microscope (SEM). The results showed that the mechanical properties of AA 6063 are highly dependent on the Mg2Si content. While the mechanical properties were improved by the increase in Mg2Si content, the extrudability has been decreased. It was also shown that the manufacturing of high-quality aliminium profiles was possible using dies by manufactured by DMLS directly from production.