Direct metal deposition (DMD) is a powder jet additive-manufacturing (AM) technique that can be used for low-cost build, repair, hardfacing and reconfiguration of forging dies. The technique has also been used to add features such as flanges and bosses to forged parts to improve their functionality. This article uses four case studies to examine this technique in detail and compares its merits and limitations to conventional and other AM/welding techniques.
Researchers at Ohio University conducted a FIERF-funded inquiry to understand what cold deformation did to additive-manufactured (AM) shapes. This understanding is critical to harnessing the advantages of both processes and improving the mechanical properties of AM parts as AM technologies continue to emerge and mature.
Century Aluminum Sebree LLC, a wholly owned subsidiary of Century Aluminum Co., announced two expansion programs at its Sebree, Ky., smelter that will increase the smelter’s production of both value-added and secondary aluminum. The programs, which are expected to be completed in the first quarter of 2019, will improve the smelter’s product mix by adding approximately 90,000 metric tons of additional billet production to the Sebree casthouse and increase the smelter’s overall output by adding 20,000 metric tons of additional secondary (scrap reprocessing) capacity.
A group of forging professionals recently gathered in Long Beach, Calif., to attend the Forging Industry Educational and Research Foundation’s (FIERF) 32nd Technical Conference. Attendees were treated to a great plant tour, two days of technology, and a chance to greet old friends and network with new ones.
Long Beach, Calif., is perhaps best known as the retirement home of the legendary cruise ship Queen Mary, which is permanently moored there and is currently an operating hotel and museum. But on Sept. 11-12, Long Beach hosted some of the forging industry’s best and brightest technical people, industry professionals, suppliers and educators at what was FIERF’s 32nd Technical Conference.
World-class scientists with high-performance computing capabilities at the Department of Energy’s (DOE) national laboratories are partnering with U.S. industries to tackle some of manufacturing’s toughest problems.
In this case study, Lawrence Livermore National Laboratory (LLNL) is working in partnership with Purdue University Northwest and steel-industry stakeholders to use their high-performance computing (HPC) modeling, simulation and visualization capabilities to optimize blast furnaces in order to reduce emissions and energy use.
Traditionally, the technology of coordinate measuring machines (CMMs) provided the benchmark for dimensional accuracy of parts and dies. During the last 20 years, however, non-contact scanning devices using laser and X-ray technologies have also proven to be versatile and accurate.