There is an ongoing demand to demonstrate the adoption and performance of unconventional and/or affordable powders in metal additive manufacturing (AM) processes targeting automotive applications. Through a multi-disciplinary collaborative effort between RioTinto Fer et Titane (Canada), Miba Sinter Austria, and the Multi-Scale Additive Manufacturing Lab (University of Waterloo, Canada), a water atomized low alloy steel (4405) was adopted for laser powder bed fusion and binder jetting to target properties required for specific power train components. The performance requirements dictate that, for both AM processes, there is a need to control the process parameters to tailor the density (spatially-control density in a range from 85 to >99.8%) and influence final mechanical properties. Additionally, design optimization (latticing) was deployed to demonstrate lightweighting of gears under specific loading conditions. This work will highlight the material performance, along with the success and technical challenges surpassed in the manufacturing of such gear demonstrators.
Learning Objectives:
- Describe the steps required to tailor the density and mechanical performance of material systems via laser powder bed fusion (and binder jetting)
- List which characterization techniques are appropriate to assess performance during optimization cycle and how to do so.
- Describe the design concepts utilized for density control and lightweighting control.
