Enhancing Metal Forging Tools and Moulds: Advanced Repairs and Optimisation Using Directed Energy Deposition Hybrid Manufacturing

Abstract

This article investigates the efficacy of directed energy deposition (DED) processes in repairing forging tools and moulds, comparing mechanical properties between specimens fabricated from conventional sheet metal and those manufactured by DED techniques. A comparative analysis reveals significant mechanical differences between subtractive and DED-manufactured specimens, emphasising the nuanced balance between tensile strength and ductility in DED-produced components influenced by layering. Notable insights from scatter plot analyses highlight distinct material behaviours, particularly layer-dependent tendencies in DED-manufactured specimens. Regression-based predictive models aid in understanding material behaviours, aiding in informed material selection for manufacturing processes. Additionally, this article underlines the advantages of DED-based repair processes, highlighting precision, material efficiency, reduced lead times, and cost-effectiveness. The article studies die and mould repair, tool restoration, and critical considerations like material compatibility and quality assurance. The study concludes by emphasising the role of hybrid manufacturing in extending product lifecycles, in conformity with specific mechanical requirements, and fabricating complex geometries, despite potential higher costs in materials and technologies. Overall, this research demonstrates the efficacy of DED processes in enhancing component reliability and lifespan in metalworking industries.