metals

Article
Case Study to Illustrate the Potential of Conformal
Cooling Channels for Hot Stamping Dies
Manufactured Using Hybrid Process of Laser Metal
Deposition (LMD) and Milling
Magdalena Cortina 1, * ID , Jon Iñaki Arrizubieta 1 , Amaia Calleja 1 , Eneko Ukar 1
and Amaia Alberdi 2 ID
1 Department of Mechanical Engineering, University of the Basque Country, Plaza Torres Quevedo 1,
48013 Bilbao, Spain; joninaki.arrizubieta@ehu.eus (J.I.A.); amaia.calleja@ehu.eus (A.C.);
eneko.ukar@ehu.eus (E.U.)
2 Tecnalia Research and Innovation—Industrial Systems Unit, Paseo Mikeletegi 7,
20009 Donostia/San Sebastián, Spain; amaia.alberdi@tecnalia.com
* Correspondence: magdalena.cortina@ehu.eus; Tel.: +34-946-017-347

Received: 12 December 2017; Accepted: 30 January 2018; Published: 1 February 2018

Abstract: Hot stamping dies include cooling channels to treat the formed sheet. The optimum
cooling channels of dies and molds should adapt to the shape and surface of the dies, so that
a homogeneous temperature distribution and cooling are guaranteed. Nevertheless, cooling ducts
are conventionally manufactured by deep drilling, attaining straight channels unable to follow
the geometry of the tool. Laser Metal Deposition (LMD) is an additive manufacturing technique
capable of fabricating nearly free-form integrated cooling channels and therefore shape the so-called
conformal cooling. The present work investigates the design and manufacturing of conformal cooling
ducts, which are additively built up on hot work steel and then milled in order to attain the final part.
Their mechanical performance and heat transfer capability has been evaluated, both experimentally
and by means of thermal simulation. Finally, conformal cooling conduits are evaluated and compared
to traditional straight channels. The results show that LMD is a proper technology for the generation
of cooling ducts, opening the possibility to produce new geometries on dies and molds and, therefore,
new products.

Keywords: additive manufacturing; laser metal deposition; hot stamping; die and mold; conformal
cooling; design optimization

1. Introduction
The die and mold industry plays a significant role in the manufacturing world [1]. This is
due to the fact that nearly all mass-produced parts are manufactured employing processes that
include dies and molds, directly affecting not only the efficiency of the process, but also the quality
of the product [2]. Moreover, increasing demand in the automotive industry for high strength and
lightweight components has led to the promotion and development of hot stamping (also known
as Press Hardening) processes [3]. Through this technique, a boron steel blank is heated until
austenization at temperatures between 900 ◦ C and 950 ◦ C inside a furnace and then transferred
to an internally cooled die set, where it is simultaneously stamped and quenched. The transformation
of austenite into martensite occurs thanks to a rapid cooling of the blank, at a temperature range of
420–280 ◦ C, along which the dies must be actively cooled at a minimum cooling rate of 27 ◦ C·s−1 [4].
The temperature of the hot stamping tool must be kept below 200 ◦ C in order to ensure the cooling of
the blank, achieve high strength and prolong the lifespan of the tools [5]. Thus, if the cooling ducts are

Metals 2018, 8, 102; doi:10.3390/met8020102 www.mdpi.com/journal/metals

Metals 2018, 8, 102 2 of 15

not adequately designed, the temperature of the tool can be increased during the productive process,
the quenching may not be successfully achieved and therefore, the final product would not meet
requirements. Moreover, the temperature of the die could be non-homogeneous, resulting in hot areas
where the quenching could not be achieved.
The efficiency of the cooling channels determines the characteristics and cooling time of the final
part. Some authors [6] relate low cooling rates and thermally induced surface defects on the component
to an inadequate cooling system. These consequences could be avoided by the optimization and new
arrangement of the cooling ducts. However, the cooling conduits are conventionally manufactured by
drilling, hence only straight channels can be generated and often attain a not uniform heat transfer.
This may lead to longer cycle times, unequal cooling and warp [7]. Thus, the employment of traditional
techniques for the manufacture of the inner cooling conducts of the stamping tools leads to restrictions
on the final geometry of the parts.
Additive manufacturing technologies such as LMD have been developed within recent years,
enabling the manufacture of high quality and fully dense metal parts. Reducing porosity is one of the
main objectives in order to achieve good quality and mechanical properties in additively manufactured
components. Some authors [8,9] perform meticulous studies in order to determine the effect of main
process parameters on the metallurgy of the parts. Additive Manufacturing offer a real solution when
manufacturing conformal cooling channels with complex geometries and, therefore, advance towards
rapid cooling [10].
There are two kinds of techniques for manufacturing conformal cooling ducts in hot stamping
molds or dies: the layer-laminated method and the powder metallurgy-based additive manufacturing,
belonging powder bed and powder nozzle technologies to the latter [11]. On the one hand,
by layer-laminated manufacturing, single layers are cut, stacked and then joined together in order
to generate a final part. This technique is used for the production of plain and geometrically simple
parts. For instance, Hölker et al. [12] studied the design of straight holes in layered extrusion dies by
joining lamellas with holes and thus creating cooling channels. On the other hand, components are
additively built up layer by layer by locally melting a metal powder bed or stream, implying freeform
manufacturing with nearly no geometric restrictions. These methods are usually performed to generate
high complexity geometries and, regarding LMD, it is frequently combined with machining, giving
rise to the so-called hybrid manufacturing.
Huskic et al. [13,14] investigated the integration of conformal cooling channels into forging dies
and hot stamping tools by using Selective Laser Melting (SLM). Results showed that the hybrid
die could withstand the mechanical loads originated during forging. In addition, Ahn et al. [15]
manufactured injection molds with conformal cooling ducts by combining direct metal rapid tooling
and machining. As a result, the designed molds highly reduced the cooling time and required
energy when compared to the conventional molds, improving the product quality. Müller et al. [16]
manufactured hybrid hot stamping dies by machining and additively building up inserts with
conformal cooling ducts. As a result, the additively manufactured channels cooled six times faster
than the conventional drilled channels. With regard to powder nozzle-based additive technologies,
Vollmer et al. [17] studied the integration and manufacturing of additively built up cooling channels for
the fabrication of hot stamping tools. For this purpose, several grooves were machined and afterwards
closed by LMD and finished by milling. From the literature review, it is noted that some research has
been carried out in the field of conformal cooling and additive manufacturing. However, the number of
references focusing on the application and suitability of these technologies to hot stamping tools is very
limited. Hence, there exists a gap in the generation of conformal channels by depositing hot work steels,
such as AISI H13 on CR7V-L, and the analysis of the resultant thermal and mechanical characteristics.
The present work aims to investigate the design and manufacturing of additively built up
conformal cooling ducts, fabricated by combining LMD with 5-axis milling. Experimental study
of laser metal deposition of AISI H13 tool steel powder on CR7V-L tool steel specimens has been
carried out for the fabrication of the adaptive cooling channels. The performance of the channels is
Metals 2018, 8, 102 3 of 15

analyzed and compared to traditional straight ducts by metallurgical, mechanical tests and thermal
analysis. Finally, the suitability of this process to a 3D geometry of higher complexity is investigated.

2. Materials and Methods

All experiments described in this work are performed on a 5-axis (three linear and two rotatory)
conventional milling center rebuilt as a laser processing machine, named Kondia Aktinos 500 (Kondia,
Elgoibar, Spain), whose work piece size capacity is 700 × 360 × 380 mm3 . In addition, a high power
Yb:YAG fiber laser source, Rofin FL010 (ROFIN-SINAR Laser GmbH, Bergkirchen, Germany), is used,
with a maximum power output of 1 kW, emitting wavelength of 1070 nm and pulse frequency range
up to 5 kHz. The laser beam is guided through an optical multi-mode fiber from the laser source to the
processing machine, generating a circular laser spot of 2 mm on the surface of the work piece, situated
at a 200 mm focal distance. The powder is fed by means of a Sulzer Metco Twin 10-C powder feeder
(Oerlikon Metco, Pfäffikon, Switzerland) and an in-house designed coaxial nozzle, EHU/Coax 2015
(UPV/EHU, Bilbao, Spain) [18], while argon is used as both drag and shielding gas.
Three different materials are used along the present investigation in order to generate the final
part: CR7V-L, AISI H13 (1.2344) (Flame Spray Technologies, Duiven, The Netherlands) and AISI 316L
(1.4404) (Erasteel, Commentry, France). On the one hand, CR7V-L hot work tool steel by Kind and
Co. Edelstahlwerk, Wiehl, Germany [19] is a special high Cr-alloyed steel commonly used in hot work
applications, such as hot forming tools of structural automobile parts. Furthermore, it is characterized
by excellent high temperature strength and wear resistance, as well as good thermal fatigue resistance.
On the other hand, AISI H13 is a Cr-Mo-V alloyed tool steel with a high level of resistance to thermal
shock and fatigue and good temperature strength. Thus, these properties make AISI H13 particularly
valuable for tooling. The chemical composition and thermal properties of the studied materials are
shown in Tables 1 and 2, respectively.

Table 1. Chemical composition (wt. %) of the used materials, data from [19–22].

Material C Si Mn Cr Mo V Ni P Fe
CR7V-L 0.42 0.50 0.40 6.50 1.30 0.80 - - Balance
AISI H13 0.39 1.00 0.40 5.20 1.40 0.90 - - Balance
AISI 316L 0.0023 0.34 0.079 18.15 2.33 - 11.75 <0.001 Balance

Table 2. Thermal properties of the used materials, data from [19–22].

Material Temperature (◦ C) 20 400 600

CR7V-L Thermal conductivity (W·m−1 ·K−1 ) 26.7 30.8 30.8
Coefficient of thermal expansion (10−6 K−1 ) 11.2 12.5 13.1
AISI H13 Thermal conductivity (W·m−1 ·K−1 ) 25 29 30
Coefficient of thermal expansion (10−6 K−1 ) - 12.6 13.2
AISI 316L Thermal conductivity (W·m−1 ·K−1 ) 15.3 20.1 22.7
Coefficient of thermal expansion (10−6 K−1 ) 16 17.5 18.5

Hence, CR7V-L slabs are used as substrate and AISI H13 metallic powder as filler material so
that the conformal cooling channels are closed. Both materials are compatible hot work tool steels
with similar thermal properties, such as thermal conductivity and coefficient of thermal expansion.
Besides, AISI 316L austenitic stainless steel is used as intermediate layer in order to relax internal stress
and improve the weldability of the materials. Otherwise, the direct deposition of AISI H13 with no
intermediate layer results in the cracking of the part. The preference of choosing AISI 316L instead
of other interface materials such as nickel alloys is due to its higher thermal conductivity and ease
of LMD.
The present investigation is performed on a 100 × 120 × 32 mm3 CR7V-L hot work steel slab,
in which two different cooling channels of six millimeters of diameter at a depth of ten millimeters
Metals 2018, 8, 102 4 of 15

below the surface are generated: one is conventionally drilled and the other additively manufactured
via LMD, see Figure 1. At first, the CR7V-L substrate is soft annealed by holding the specimen at
Metals 2018, 8, x FOR PEER REVIEW 4 of 15
840 ◦ C for five hours with slow cooling in furnace (Helmut ROHDE GmbH, Prutting, Germany) in
Metals 2018, 8, x FOR PEER REVIEW 4 of 15
via LMD,
order to reduce itssee
highFigure 1. At first,
hardness, the CR7V-L
59.6 HRC, and substrate
allowis soft annealed by holding
its preparation the specimen
by machining. at 840
This preparation
°C for five hours with slow cooling in furnace (Helmut ROHDE GmbH, Prutting, Germany) in
◦ V-notch for the LMD operation. Once theorder
consists of
via directly
LMD, seedrilling
Figure 1.aAtfirst
first,duct and milling
the CR7V-L a 45
substrate is soft annealed by holding the specimen at 840
to reduce its high hardness, 59.6 HRC, and allow its preparation by machining. This preparation
preparatory
°C phase
for five is
hoursconcluded,
with slow the part
cooling inis ready
furnace to be
(Helmut submitted
ROHDE
consists of directly drilling a first duct and milling a 45° V-notch for tothe
GmbH, theLMD
LMD
Prutting,process,
Germany)
operation. whose
Once in aim is to
theorder
close the to reduce
milled its
V-notch high hardness,
so that an 59.6 HRC,
additively and allow its
manufactured preparation
channel by machining.
comparable
preparatory phase is concluded, the part is ready to be submitted to the LMD process, whose aim is This
to preparation
the drilled one is
consists
to close of
the directly
milled drilling
V-notch soa first
that duct
an and
additivelymilling a 45°
manufactured V-notch
channel for the LMD
comparable
generated. Moreover, accessibility issues and geometric restrictions are considered for verifying the operation.
to the drilled Once
one the
preparatory phase is concluded, the part
issuesis and
ready to be submitted to are
the considered
LMD process, whose aim is
suitabilityisofgenerated.
the availableMoreover, accessibility
nozzle when manufacturing geometric
therestrictions
part. for verifying
tothe
close the milled
suitability V-notch
of the so nozzle
available that anwhen
additively manufactured
manufacturing channel comparable to the drilled one
the part.
is generated. Moreover, accessibility issues and geometric restrictions are considered for verifying
the suitability of the available nozzle when manufacturing the part.

Figure 1. (a) Substrate before LMD; (b) Computer Aided Design (CAD) model to be processed.
Figure 1. (a) Substrate before LMD; (b) Computer Aided Design (CAD) model to be processed.
Along the LMD process, two different materials are deposited: AISI 316L stainless steel as
Along intermediate
LMDlayer
theFigure (a) and
1. process, AISItwo
Substrate H13 hot
before work(b)
different
LMD; steel for the surface
materials
Computer coating.
areDesign
Aided Different
deposited:
(CAD) deposition
AISI
model to 316L strategies
stainless steel as
be processed.
and process parameters are used for attaining sound clads with each material. Firstly, AISI 316L is
intermediate layer and AISI H13 hot work steel for the surface coating. Different deposition strategies
usedAlong
in order
thetoLMD
seal the V-notch
process, twoanddifferent
hence generate
materialsthe are
channel, while AISI
deposited: AISIH13316Lis added oversteel
stainless it as
and process parameters
until the upper are used
surface of the for
part attaining
is work
reached. sound
For clads with each316Lmaterial. Firstly, AISI 316L is
intermediate layer and AISI H13 hot steel forthat
thepurpose, the AISI
surface coating. intermediate
Different deposition layer is
strategies
used in order
and process parameters are used for attaining sound clads with each material. Firstly, AISI 316L isover it
to
deposited seal
on the
the V-notch
right and and
left hence
slopes of generate
the milled the
V-notch channel, while
alternately, AISI
following aH13 is added
longitudinal
zigzag
until the used
upper cladding
surface
in order strategy
of
to seal the in which
the part
V-notch thehence
is reached.
and surface
For ofthat
generatethe purpose,
partchannel,
the and the
thenozzle
AISI
while AISIare
316L perpendicularly
H13 intermediate
is added over it layer is
orientated as shown in Figure 2.
depositeduntil
on the upper
right and
surfaceleftofslopes
the part ofisthe milledFor
reached. V-notch alternately,
that purpose, the AISIfollowing a longitudinal
316L intermediate layer iszigzag
claddingdeposited
strategy onin the
whichrighttheandsurface
left slopes of the
of the partmilled
and V-notch
the nozzlealternately, following a longitudinal
are perpendicularly orientated as
shown inzigzag
Figurecladding
2. strategy in which the surface of the part and the nozzle are perpendicularly
Cladding on left side
orientated as shown in Figure 2.

Cladding on right side

Cladding on left side

Nozzle
Cladding on right side
Powder flux …
Laser beam
Deposited material
Nozzle
Substrate
Layer 1 Powder flux Layer 2 Layer 3 … Layer N
Laser beam
Deposited
Figure material
2. Deposition strategy of the AISI 316L intermediate layer.
Substrate
Once the channel is closed, AISI H13 is added by alternating longitudinal with transversal
Layerlaser
directions when 1 cladding until the desired height
Layeris2reached, Layer 3 in Figure 3. Directionality
as shown Layer N
within the mechanical properties and residual stress of the deposited material that may lead to the
generation of Figure Figure 2. Deposition
Deposition
2. thereby
cracks are strategy
strategy
avoided. ofofthe
theAISI
AISI 316L
316L intermediate
intermediatelayer.
layer.

Once the channel is closed, AISI H13 is added by alternating longitudinal with transversal
Once the channel
directions is closed,
when laser claddingAISI H13
until the is added
desired heightby alternating
is reached, longitudinal
as shown with transversal
in Figure 3. Directionality
directionswithin
whenthe laser cladding
mechanical until the
properties desired
and height
residual stress is
of reached, as shown
the deposited inthat
material Figure
may 3. Directionality
lead to the
generation of cracks are thereby avoided.
within the mechanical properties and residual stress of the deposited material that may lead to the
generation of cracks are thereby avoided.
Metals 2018, 8, 102 5 of 15
Metals 2018, 8, x FOR PEER REVIEW 5 of 15

Metals 2018, 8, x FOR PEER REVIEW 5 of 15

Figure 3. Deposition strategy of AISI H13.

Figure 3. Deposition strategy of AISI H13.
As far as the process parameters are concerned, different values are used for the deposition of
Aseach
far material and are parameters
as the process presented in are
Table 3, while thedifferent
concerned, results attained
valueswhen finishing
are used the deposition
for the deposition of
of AISI 316L
each material and presented
and are AISI H13 are
in shown inwhile
Table 3, Figurethe4. results attained when finishing the deposition of
AISI 316L and AISI H13 are shown Figure 3. Deposition strategy of AISI H13.
in Figure 4.
Table 3. Laser Metal Deposition (LMD) process parameters regarding deposited materials.
As far as the process parameters are concerned, different values are used for the deposition of
Table 3. Laserand
each material Metal Process
Deposition
are presented in Parameters
(LMD)
Table process
3, while theparameters AISI 316L finishing
regarding
results attained when AISIthe
deposited H13deposition
materials.
of AISI 316L andContinuous
AISI H13 arewave
shown(CW) laser power
in Figure 4. (W) 625 600
Scan velocity (mm·min−1) 550 450
Process Parameters AISI 316L AISI H13
Table 3. Laser MetalTrack offset(LMD)
Deposition (mm)process parameters regarding 1.4 deposited materials.
1
Continuous waveOverlap(CW) laser(%) power (W) 625 30 60050
Process Parameters−1 −1 AISI 316L AISI H13
ScanPowder
velocity
flow(mmrate·min
(g·min) ) 550 5 4503.3
Continuous wave (CW) laser power (W) 625 600
PowderTrack offset (mm)
preheating temperature (°C) 1.4 60 1
Scan velocity (mm·min−1) 550 450
Overlap
Protective gas (%)
flow rate
Track offset (mm) (L·min −1) 30
1.4 14 1
50
Powder flow rate (g
Overlap ·min−1 )
(%) 5
30 50 3.3
Powder preheating ◦
Powder flowtemperature
rate (g·min−1) ( C) 5 60 3.3
Protective
Powdergas flow rate
preheating temperature −
(L·min (°C)1) 6014
Protective gas flow rate (L·min−1) 14

Figure 4. Final part after finishing the LMD process.

Figure 4. Final part after finishing the LMD process.
Following the experiments, the part
Figure 4. Final partisafter
hardened by heating
finishing the LMD at process.
1050 °C for 15 min and quenching
in water.Following
The component is then the
the experiments, ground
part isso that thebydesired
hardened surface
heating at 1050 °Cquality is attained.
for 15 min In addition,
and quenching
in water. The component is then ground so that the desired surface quality is attained.
drill holes of ten millimeters length are conducted and M10 fine threaded◦inside the channels in order In addition,
Following theofexperiments,
drill holes ten millimeters the part
length is hardened by heating at 1050 C forchannels
15 mininand quenching
to enable the threading of push inareconnectors
conducted and
andM10 fineproceed
then threaded inside
to the the
thermal and order
mechanical
in water. The component
to enable is thenofground
the threading push in so that theand
connectors desired surfacetoquality
then proceed is attained.
the thermal In addition, drill
and mechanical
analyses.
analyses.
holes of ten millimeters length are conducted and M10 fine threaded inside the channels in order to
enable the threading of push in connectors and then proceed to the thermal and mechanical analyses.
Metals 2018, 8, 102 6 of 15
Metals 2018, 8, x FOR PEER REVIEW 6 of 15

Metals 2018, 8, x FOR PEER REVIEW 6 of 15

3.
3. Results
Results
3. Results of Microstructure and Internal Defects
3.1.
3.1. Analysis
Analysis of Microstructure and Internal Defects
3.1. In
In order
orderofto
Analysis analyze
analyze the
the macrostructure
toMicrostructure macrostructure and microstructure of
and microstructure
and Internal Defects of the
the deposited
deposited material
material and
and find
find
possible internal defects, the cross section of samples was cut, polished and etched. Marble
possible internal defects, the cross section of samples was cut, polished and etched. Marble solution solution
In order to analyze the macrostructure and microstructure of the deposited material and find
was
wasusedusedtotoreveal
revealmacrostructure
macrostructure andand
microstructure of theofsubstrate
microstructure and deposited
the substrate material.
and deposited Images
material.
possible internal defects, the cross section of samples was cut, polished and etched. Marble solution
of cross sections
Images are offered,
of cross sections where the
are offered, macrostructure
where properties
the macrostructure of the clads
properties areclads
of the shown.
are The strategy
shown. The
was used to reveal macrostructure and microstructure of the substrate and deposited material.
of deposition of the different layers can be appreciated in Figure 5a, where the deposition
strategy of deposition of the different layers can be appreciated in Figure 5a, where the depositiondirections
Images of cross sections are offered, where the macrostructure properties of the clads are shown. The
are indicated.
directions are indicated.
strategy of deposition of the different layers can be appreciated in Figure 5a, where the deposition
directions are indicated.

Figure 5. Metallography of the (a) deposited layers; (b) detail of a pore.

Figure 5. Metallography of the (a) deposited layers; (b) detail of a pore.
Figure 5. Metallography of the (a) deposited layers; (b) detail of a pore.
As far as metallurgical quality is concerned, no cracks or other intra- or inter-layer defects are
As far
detected, as metallurgical
except quality is
for some intra-layer concerned,
pores no
of less ofno
100cracks or other intra-
µm diameter. or inter-layer
An example is shown defects are
in Figure
As far as metallurgical quality is concerned, cracks or other intra- or inter-layer defects are
detected,
5b, except
where except
a higherfor some intra-layer pores of less of 100 µm diameter. An example is shown in
detected, formagnification
some intra-layerof pores
an intra-layer
of less of region
100 µmisdiameter.
shown andAn aexample
pore ofisapproximately
shown in Figure75
Figure
µm 5b, where
canabe higher magnification of an intra-layer region is shown and a pore of approximately
5b, diameter
where a higher noted.
magnification of an intra-layer region is shown and a pore of approximately 75
75 µmFurthermore,
diameter canabe noted.
detail of the microstructures of substrate and clad is shown in Figure 6. The
µm diameter can be noted.
Furthermore,
substrate (Figure a presents
6a) detail ofa the microstructures
martensitic of substrate
microstructure and cladtempered
characteristic is shown in Figure 6.
Furthermore, a detail of the microstructures of substrate and clad ofis shown in CR7V-L.
Figure 6.From
The
The
Figuresubstrate (Figure
6b,(Figure
it may 6a) presents
be noted that theamorphology
martensitic microstructure characteristicdeposited
of the microstructure of tempered
AISICR7V-L.
substrate 6a) presents a martensitic microstructure characteristicofofthe
tempered CR7V-L. H13
Fromis
From Figure
principally 6b, it may
martensitic, be noted
composed that
ofthe morphology
retained austeniteof the
and microstructure
some of
undissolved the deposited
carbides AISI H13
distributed
Figure 6b, it may be noted that the morphology of the microstructure of the deposited AISI H13 is
is
in principally
a tempered martensitic, composed of retained austenite and some undissolved carbides distributed
martensitecomposed
matrix.
principally martensitic, of retained austenite and some undissolved carbides distributed
ininaatempered martensite matrix.
tempered martensite matrix.

Figure 6. Microstructure of (a) the substrate; (b) the deposited material.

Figure 6. Microstructure of (a) the substrate; (b) the deposited material.
Figure 6. Microstructure of (a) the substrate; (b) the deposited material.
Hence, the analysis of the microstructure and the quality of the deposited material result to be
satisfactory
Hence,and
the no anomalies
analysis of theare found.
microstructure and the quality of the deposited material result to be
Hence, the analysis of the microstructure
satisfactory and no anomalies are found. and the quality of the deposited material result to be
satisfactory and no anomalies are found.
Metals 2018, 8, 102 7 of 15

3.2. Thermal Analysis

Metals 2018, 8, x FOR PEER REVIEW 7 of 15

3.2.1.3.2. Thermal
Metals 2018, 8,
Cooling xAnalysis
FOR PEER REVIEW
Capacity 7 of 15

In
3.2.order
Thermal
3.2.1. Cooling toAnalysis
analyze the cooling capacity of the drilled and additively built up channels,
Capacity
the specimen is monitored with an Optris PI 160 infrared camera (Optris Infrared Sensing, Portsmouth,
In order to analyze the cooling capacity of the drilled and additively built up channels, the
3.2.1.
USA),Cooling
NH, specimen while Capacity
the emissivity
is monitored with an of the material
Optris is evaluated
PI 160 infrared with aInfrared
camera (Optris type K Sensing,
thermocouple.
Portsmouth,For that
purpose,
NH, Inthe
USA), sample
order is
theheated
to analyze
while theby
emissivity scanning
cooling the surface
of thecapacity
material ofisthe with the
drilled
evaluated withlaser
and at 1000
additively
a type W. up
built Thechannels,
K thermocouple. scanner sweeps
the
For that
specimenthe
a rectangular
purpose, is monitored
area and its
sample with anby
is thermal
heated Optris PI 160
evolution
scanning is infrared
the surface camera
examined with the(Optris
both with atInfrared
laser active W.Sensing,
1000and inactive
The Portsmouth,
scannerwater-cooling.
sweeps
ThreeaNH, USA),
points
rectangular while
are the
andemissivity
monitored:
area one of
its thermal for the material
each
evolution channel is evaluated
is examined (LMD withactive
a typeand
both manufactured
with K thermocouple.
and drilled)
inactive For
andthat
water-cooling. a third
one for the center of the part, while a water flow of 1 L·min is inserted through thesweeps
purpose,
Three the
points sample
are is
monitored:heated by
one scanning
for each the
channel surface
(LMD with the −laser
1
manufactured at 1000
and W. The
drilled) scanner
and a third one
connectors
a rectangular
for the threaded.
center ofarea
theand
part, itswhile
thermal evolution
a water flow ofis 1examined
L·min−1 isboth withthrough
inserted active andtheinactive water-cooling.
connectors previously
previously
Three points
threaded. are monitored: one for each channel (LMD manufactured and drilled) and a third one
On the one hand, the cooling capacity when the laser and the cooling are active is studied.
for the center of the part, while a water flow of 1 L·min −1 is inserted through the connectors previously
On the one hand, the cooling capacity when the laser and the cooling are active is studied. Along
Alongthreaded.
this test, the laser and the cooling work simultaneously and maximum temperatures of around
this test, the laser and the cooling work simultaneously and maximum temperatures of around 60 °C
60 ◦ Care
arereached.
reached.
On the one
Both
Both
hand, ducts
ducts thecool cool
cooling the part
capacity
the part
down
downwhen
equally
the
equally laser
so that
sothe
and that the
thepart
coolingpart
doesare
does
notactive
not heat
is studied.
heat up;
up;
however,
however,
Along
the
the temperature
temperature regarding
this test, the laser and the
regarding the
the LMD
cooling
LMD channel
work
channel is slightly
simultaneously
is slightly higher,
and
higher, it as
canitbe
maximum
as can be appreciated
temperatures
appreciated in 7.
inofFigure
around Figure
60 °C 7.
are reached. Both ducts cool the part down equally so that the part does not heat up; however, the
temperature regarding the LMD channel is slightly higher, as it can be appreciated in Figure 7.

Figure 7. Cooling capacity when laser and water-cooling are both active.
Figure 7. Cooling capacity when laser and water-cooling are both active.
On the otherFigure
hand, 7.the cooling
Cooling capacity
capacity after
when a and
laser temperature of 100
water-cooling are°C is active.
both reached is analyzed. In
this the
On case,other
the water-cooling remains inactive
hand, the cooling capacityuntil a temperature
after valueof
a temperature of100 ◦ Cisisaccomplished.
100 °C The
reached is analyzed.
On the
water-cooling other
is hand,
then the cooling
activated, withcapacity
the after
subsequenta temperature
temperature of 100 °C
descent is reached
and ◦
cooling
In this case, the water-cooling remains inactive until a temperature value of 100 C is accomplished. is analyzed.
down of In
the
this case, the water-cooling
part. The temperatures remains
obtained for inactive
both until
channels a temperature value
share temperature of 100
once again similar °C is
values, accomplished. The
The water-cooling is then activated, with the subsequent descent andwith a maximum
cooling down of the
water-cooling
difference of 5 is
°Cthen
and activated, withhigher
being slightly the subsequent
on the LMD temperature descent
duct, as shown and cooling
in Figure 8. down of the
part. The temperatures obtained for both channels share once again similar values, with a maximum
part. The temperatures obtained for both channels share once again similar values, with a maximum
difference ◦ C and being slightly higher on the LMD duct, as shown in Figure 8.
of 5 of
difference 5 °C and being slightly higher on the LMD duct, as shown in Figure 8.

Figure 8. Cooling capacity when the water-cooling is active after reaching 100 °C.

Figure 8. Cooling capacity when the water-cooling is active after reaching 100 °C.
Figure 8. Cooling capacity when the water-cooling is active after reaching 100 ◦ C.
Metals 2018, 8, 102 8 of 15

Metals 2018, 8, x FOR PEER REVIEW 8 of 15

By comparing the cooling capacity of the LMD manufactured and drilled channels on both tests
MetalsBy
2018, 8, x FOR PEERtheREVIEW 8tests
of 15
performed, itcomparing
is concluded cooling capacity
that both ductsofwork
the LMD manufactured
similarly during and drilled channels
the heating on both
and cooling cycles with
performed, it is concluded that both ducts work similarly during the heating and cooling cycles with
a very slight differencethe
Byslight
comparing on their temperature values. This difference can be due to theonexistence of the
a very differencecooling
on theircapacity of the
temperature LMD manufactured
values. This differenceand
candrilled
be duechannels bothoftests
to the existence the
AISI performed,
316L stainless it is steel intermediate
concluded that both layer,work
ducts whose thermal
similarly conductivity
during the heating isand
noticeably
cooling lowerwith
cycles than the
AISI 316L stainless steel intermediate layer, whose thermal conductivity is noticeably lower than the
ones aones
regarding
slightAISI
veryregarding H13H13
difference
AISI and CR7V-L
onand
their tool
toolsteels.
temperature
CR7V-L The
values.
steels. thermal
TheThis effect
difference
thermal effect of
can
of the
be
the stainless
due to the
stainless steel intermediate
existence
steel of the
intermediate
AISI
layerlayer 316L
is therefore stainless
is therefore steel
analyzed intermediate
byby
analyzed means
means layer, whose
ofofthermal thermal
thermalsimulations.
simulations.conductivity is noticeably lower than the
ones regarding AISI H13 and CR7V-L tool steels. The thermal effect of the stainless steel intermediate
3.2.2.layer
Thermal
3.2.2. is Simulations
therefore
Thermal analyzed by means of thermal simulations.
Simulations
The
3.2.2.selected
The LMD
selected
Thermal LMD strategy
Simulations strategy includes
includesthe thedeposition
deposition of ofaastainless
stainless steel
steel intermediate
intermediate layer,layer,
whosewhose
thermal
thermal properties
properties differdiffer
fromfromthethe onesofofthe
ones theoriginal
original part.
part.Moreover,
Moreover, thethe surface finish
surface of the
finish ofLMD
the LMD
The is
channel selected
coarser LMD
than strategy includes
regardingthe deposition of a stainless steel intermediate layer, whose
channel is coarser than thetheoneoneregarding the
the drilled duct.
drilled duct.Hence,
Hence,the theinfluence
influence of the intermediate
of the intermediate
thermal
layer properties
andsurface
the surface differ from
finish the ones
is studied of the original part. Moreover, the surface finish of the LMD
layerchannel
and the is coarser finish
than is studied
the one by by
regarding
means
means
the of of
drilled
finite
finiteduct.
elements(FE)
elements
Hence,
(FE)thermal
the
thermal simulations,
influence
simulations, where
of the where the
intermediate
the effect of both issues on the thermal conductivity and cooling process of the part are analyzed.
effectlayer
of both issues
andthetheone on
surface the thermal
finish conductivity and cooling process of the part are analyzed.
On hand, the is studied
results of by
themeans
thermalof finite elements
simulations for(FE)
boththermal
drilledsimulations,
and LMD cooling where
On
the the one
effect of hand,issues
both the results
on the of the thermal
thermal simulations
conductivity and for both
cooling drilled
process of and
the LMD
part are cooling channels
analyzed.
channels along a 120 s period are shown and compared to real results in Figure 9. A good
alongcorrespondence
a 120
Onstheperiod are
one is
hand, shown and
the results
attained, as thecompared
ofrelative
the thermal to real
error results in
simulations
committed Figure
isfor both 5%,
below 9. Awhat
drilledgood
and correspondence
LMD cooling
involves a high is
channels
attained, as the along a
relative 120
error
reliability of the simulations.s period
committed are shown
is below and5%,compared
what to
involves real
a results
high in Figure
reliability of 9.
the A good
simulations.
correspondence is attained, as the relative error committed is below 5%, what involves a high
reliability
(a)
of the simulations. (b)
Drilled cooling channel LMD cooling channel
100 100
(a) (b)
Drilled cooling channel Simulation LMD cooling channel Simulation
[°C] [°C]

[°C] [°C]

80
100 80
100
Real Real
Temperature

Temperature

60 Simulation 60 Simulation
80 80
Real Real
Temperature

Temperature

40
60 40
60
20
40 20
40

200 200
0 20 60 80 100 120 40 0 20 40 60 80 100 120
0 0
Time [s] Time [s]
0 20 40 60 80 100 120 0 20 40 60 80 100 120
Figure 9. Simulation
Time [s] and real results for (a) drilled; (b) LMD cooling
Timechannels.
[s]
Figure 9. Simulation and real results for (a) drilled; (b) LMD cooling channels.
Figure
On the other 9. Simulation
hand, and real
a comparison results for
between the(a)evolutions
drilled; (b)of
LMD
thecooling channels.of both ducts is
temperatures
On
shownthe inother hand,
Figure a comparison
10. Therefore betweentothe
and according theevolutions
simulations,ofitthecantemperatures
be concluded of thatboth
bothducts
On the
channels other
work hand, aand
similarly comparison
the effect between
of surfacethefinish
evolutions
together of with
the temperatures
the influence ofofboth
the ducts is
stainless
is shown in Figure 10. Therefore and according to the simulations, it can be concluded that both
shown
steelworkin Figure 10.
intermediate Therefore
layer and according to the simulations, it can be concluded that both
channels similarly andis the
negligible.
effect of surface finish together with the influence of the stainless steel
channels work similarly and the effect of surface finish together with the influence of the stainless
intermediate layer is negligible.
steel intermediate layer is negligible.
Cooling capability comparison
100
Cooling capability comparison Drilled
[°C] [°C]

80
100
LMD
Temperature

60 Drilled
80
LMD
Temperature

40
60
20
40

200
0 20 40 60 80 100 120
0
Time [s]
0 20 40 60 80 100 120
Figure 10. Cooling capacity comparison between
Time [s]the drilled and the LMD channels.

Hence, Figure 10. Cooling are

the simulations capacity comparison
satisfactory andbetween theducts
the two drilledexperience
and the LMD channels.
the same cooling. The
Figure 10. Cooling capacity comparison between the drilled and the LMD channels.
temperature of the part is reduced from 80 °C until 30 °C in 120 s for both channels.
Hence, the simulations are satisfactory and the two ducts experience the same cooling. The
Hence, the ofsimulations
temperature are satisfactory
the part is reduced and30the
from 80 °C until °C intwo
120 sducts experience
for both channels. the same cooling.
The temperature of the part is reduced from 80 ◦ C until 30 ◦ C in 120 s for both channels.
Metals 2018, 8, 102 9 of 15

3.3. Mechanical Analysis

3.3.1. Compression Test

Once the cooling capacity of the additively built up channel of the manufactured part is positively
compared to the drilled duct, a mechanical validation of the specimen is accomplished. The service
conditions of a die are limited to a maximum pressure of 12–15 MPa at a velocity of 50–80 mm·s−1 .
However, and because of the restrictions of the available compression machine, the tests are realized
at a velocity of 40 mm·min−1 . The technical characteristics of the employed machine are included
in Table 4.

Table 4. Technical characteristics of the compressive machine.

Technical Characteristics of the SDE Compressive Machine (MEM-101/SDC)

Capacity (kN) 300
Maximum velocity (mm·min−1 ) 40
Stroke (mm) 400

Two different experiments are carried out attending to the pressure applied. On the first
compression test, CT1, the force is applied on the whole surface of the specimen, while on the second
compression test, CT2, the pressure is localized on the channels. For that purpose, two ten millimeters
width AISI 1020 rectangular bars are placed over the channels. For each compression test, two different
pressures are applied: one according to the maximum pressure on service, 15 MPa, and another with
a safety factor of two when possible, resulting in a pressure value of 30 MPa. Regarding the CT1-2 test,
it is not possible to reach 30 MPa because of exceeding the maximum force of 300 kN to be applied
by the compressive machine, 25 MPa are therefore applied. The parameters of the compression tests
performed are shown in Table 5.

Table 5. Realized compression tests.

Test Applied Pressure (MPa) Surface (mm2 ) Applied Force (kN)

CT1-1 15 11,677.5 175.16
CT1-2 25 11,677.5 291.94
CT2-1 15 2404 36.06
CT2-2 30 2404 72.12

The evolution of the applied force regarding the stroke of the machine on the most critical executed
tests is shown in the following charts hereunder shown in Figure 11. At first, the value of the force is
zero because of the existing gap between the upper compressor plate and the part. Then, a minimum
value of force is reached, after which a linear increasing tendency of the force with regard to the stroke
of the upper plate is appreciated.
The part is visually analyzed after the realization of the mechanical tests and no changes are
detected. Possible cracking and deformation are inspected by means of penetrating liquids and a dial
gauge, respectively. Results show that no distortions or cracks are present in the deposited area.
Thus, it is concluded that the additively built up channel withstands the service pressure of 15 MPa,
even with a safety factor of two. The manufactured specimen subsequently meets the mechanical
requirements necessary in hot stamping dies.
Metals 2018, 8, 102 10 of 15
Metals 2018, 8, x FOR PEER REVIEW 10 of 15
Metals 2018, 8, x FOR PEER REVIEW 10 of 15

Figure 11. (a) CT1-2; (b) CT2-2 set-ups and results.

Figure 11. (a) CT1-2; (b) CT2-2 set-ups and results.
3.3.2. Hardness and Roughness Tests
Figure 11. (a) CT1-2; (b) CT2-2 set-ups and results.
3.3.2. Hardness and Roughness
Additionally, Tests
with regard to the compression tests, hardness is measured both superficially and
across the different layers deposited. Surface measurements were realized at 49 N (5 kgf) with an
3.3.2. Hardness
Additionally, and Roughness
with regard Tests
to the
Ernst Compumet SC hardness testercompression tests,SA,
(ERNST Härteprüfer hardness is measured
Lamone, Switzerland), both superficially
obtaining an
and across the different
Additionally,
average hardness layers
with 55.45 deposited.
of regard to the
HRC, isSurface
compression
which measurements
tests,
higher than thehardness were
is measured
50 HRC value realized
required byboth at 49 N (5 kgf)
the superficially
specification and with
across
an Ernst ofthe
thedifferent
Compumet tool. The hardness
SClayers
hardness measurements
deposited.
testerSurface along
(ERNST the cross section
measurements
Härteprüfer wererealized
were
SA, performed
Lamone, at 2.9
at 49 N (5N (0.3
kgf)kgf)
Switzerland), with an
obtaining
Ernst using a micro-Vickers
Compumet SC hardness
hardness testertester, Future-Tech
(ERNST FM-800SA,
Härteprüfer (Future-Tech
Lamone, Corp., Kawasaki,obtaining
Switzerland), Japan), an
an average hardness of 55.45 HRC, which is higher than the 50 HRC value required by the specification
and the dwell time was 12 s. The Vickers hardness values across the different layers of material are
of theaverage
tool.shown
Thehardness
hardness of 55.45 HRC, whichalong
measurements
in Figure 12.
is higherthethan
crossthe 50 HRC
section value
were required by
performed at the
2.9 specification
N (0.3 kgf) using
of the tool. The hardness measurements along the cross section were performed at 2.9 N (0.3 kgf)
a micro-Vickers hardness tester, Future-Tech FM-800 (Future-Tech Corp., Kawasaki, Japan), and the
using a micro-Vickers hardness tester, Future-Tech FM-800 (Future-Tech Corp., Kawasaki, Japan),
dwell time was 12 s. The Vickers hardness values across the different layers of material are shown
and the dwell time was 12 s. The Vickers hardness values across the different layers of material are
in Figure
shown12.in Figure 12.

Figure 12. Vickers hardness values of the deposited materials and substrate.

Figure 12. Vickers hardness values of the deposited materials and substrate.
Figure 12. Vickers hardness values of the deposited materials and substrate.

On the one hand, the AISI H13 upper layer generally presents similar hardness values than the
CR7V-L substrate. However, the superficial area of the AISI H13 layer presents a slightly lower hardness
 Metals 2018, 8, x FOR PEER REVIEW 11 of 15
Metals
Metals 2018,
2018, 8, 8,
102x FOR PEER REVIEW 11 of
1115
of 15
On the one hand, the AISI H13 upper layer generally presents similar hardness values than the
CR7V-L substrate.
On the one hand, However,
the AISIthe H13superficial
upper layer area of the AISI
generally H13similar
presents layer presents
hardnessavaluesslightly
thanlower
the
hardness
of CR7V-L
523.8 HV. ofOn
523.8
the HV.
substrate. otherOn
However, the the
hand, other
as it hand,
superficial
was as it wasof
area
expected, expected,
thethe AISIthe
hardnessH13 hardness
of of the intermediate
layerintermediate
the presents a slightly
AISI 316L AISI
lowerlayer
316L layerofis523.8
hardness
is considerably considerably
lower.HV.This lower.
On isthedue This
other is mechanical
hand,
to the dueastoitthe
wasmechanical
expected, properties
propertiestheof hardness of the
the material material
of the itself, maximal
intermediate
itself, whose whose
AISI
maximal
316L
hardness layerhardness value
is considerably
value is of 200 HV is[23],
lower.of This
200 HV
is due[23],
approximately.to theapproximately.
mechanical
With regard With
properties regard tomean
roughness,
of the material
to roughness, meanRa,
itself, whose
roughness,
roughness,
maximal Ra,
hardnessis measured
value isalong
of the
200 cladding
HV [23], direction with
approximately. a profilometer,
With regard
is measured along the cladding direction with a profilometer, Taylor Hobson Form Talysurf Series Taylor
to Hobson
roughness, Form 2
mean
Talysurf
roughness,
(Taylor Series
Hobson, 2 (Taylor
Ra,Leicester,
is measured Hobson,
UK), along Leicester,
the cladding
obtaining UK), obtaining
direction
a Ra value a
with
of 3.11 Ra
µm. value of 3.11
a profilometer, µm.
The hardnessTaylor The hardness
Hobson Form
and roughness and
values
roughness values of the final part are therefore satisfactory according toofthe materials and technology
of Talysurf
the final Series
part 2 (Taylor
are Hobson,
therefore Leicester,
satisfactory UK),
according obtaining a Ra value
to the materials and 3.11 µm. The
technology hardness
employed. and
employed.values of the final part are therefore satisfactory according to the materials and technology
roughness
3.4.employed.
3D Conformal Cooling
3.4. 3D Conformal Cooling
3.4.After verifyingCooling
3D Conformal the use of LMD for generating suitable conformal cooling channels on hot stamping
After verifying the use of LMD for generating suitable conformal cooling channels on hot
tools, the ability of the process with regard to more complex geometries is studied. For that purpose,
stamping
After tools, the ability
verifying the useof the
of process
LMD for with regard tosuitable
generating more complex geometries
conformal coolingischannels
studied. Foron that
hot
the following geometrical challenge shown in Figure 13 is proposed, where the cooling duct is perfectly
purpose, the
stamping following
tools, geometrical
the ability challenge
of the process with shown
regard into Figure 13 is proposed,
more complex geometries where the cooling
is studied. For duct
that
adapted to the shape of the part.
is perfectly
purpose, theadapted
following to geometrical
the shape ofchallenge
the part. shown in Figure 13 is proposed, where the cooling duct
is perfectly adapted to the shape of the part.

Figure 13. (a) Isometric view; (b) cross section of the 3D conformal cooling CAD model.
Figure 13. (a) Isometric view; (b) cross section of the 3D conformal cooling CAD model.
Figure 13. (a) Isometric view; (b) cross section of the 3D conformal cooling CAD model.
The experimental procedure and methodology followed in this case is analogous to those
The experimental procedure and methodology followed in this case 3is analogous to those
previously detailed in Section
The experimental 2. Materials
procedure and Methods.
and methodology The 100in× 70
followed this× 70 mm
case CR7V-L
is analogoussubstrate
3 CR7V-L is
to those
previously detailed in Section 2. Materials and Methods. The 100 × 70 × 70 mm substrate
firstly soft detailed
previously annealedinso that the
Section machining
2. Materials preliminary
and to the
Methods. The 100LMD
× 70 ×process
70 mm3 is eased, substrate
CR7V-L attaining isa
is firstly soft annealed so that the machining preliminary to the LMD process is eased, attaining
hardness
firstly softofannealed
30–35 HRC, see Figure
so that 14.
the machining preliminary to the LMD process is eased, attaining a
a hardness of 30–35 HRC, see Figure 14.
hardness of 30–35 HRC, see Figure 14.

Figure 14. (a) Substrate before LMD; (b) CAD model after the preparatory machining.
Figure 14. (a) Substrate before LMD; (b) CAD model after the preparatory machining.
OnceFigure 14. (a) Substrate
the preparatory before
milling LMD;
stage is (b) CAD model
concluded, theafter the preparatory
additive closure ofmachining.
the cooling duct is
conducted by preparatory
Once the the 5-axis deposition of AISI
milling stage 316L and AISI
is concluded, H13. In closure
the additive this case, a suitable
of the coolingbuilding
duct is
Once the preparatory milling stage is concluded, the additive closure of the cooling duct is
conducted by the 5-axis deposition of AISI 316L and AISI H13. In this case, a suitable building
conducted by the 5-axis deposition of AISI 316L and AISI H13. In this case, a suitable building strategy
is developed for the execution of the LMD process by using the CAD model (NX 11, Siemens Industry
Metals
Metals 2018,
2018,8,8,x102
FOR PEER REVIEW 12
12 of
of 15
15
Metals 2018, 8, x FOR PEER REVIEW 12 of 15
strategy is developed for the execution of the LMD process by using the CAD model (NX 11, Siemens
strategy
SoftwareisSoftware
Industry developed
Ltd., Frimley,
Ltd.,forSurrey,
the execution
Frimley, UK, ofUK,
2017)
Surrey, the LMD
data process
to generate
2017) data totheby deposition
using the
generate the CAD model
paths. First
deposition (NX 11,
of all,
paths. Siemens
AISI
First of316L
all,
Industry
is used Software
for V-notch Ltd.,
sealingFrimley,
(Figure Surrey,
15a). UK,
The 2017) data
material is to generate
added the
following
AISI 316L is used for V-notch sealing (Figure 15a). The material is added following a triangledeposition
a triangle paths.
geometryFirst ofthat
so all,
AISI 316L
the material
geometry is used
so added
that the for V-notch
inmaterial
one sideadded sealing (Figure
of the conduct
in one side 15a).
does
ofnot The material
theinterfere
conduct with is
doesthe added
notmaterial following
interfereadded a
on the
with the triangle
other
material
geometry
side and so
the that
conductthe material
is added
perfectly in
closed. one side of
Afterwards, the
AISI conduct
H13 is does
addednot interfere
until
added on the other side and the conduct is perfectly closed. Afterwards, AISI H13 is added until thethe with
upper the
surfacematerial
of the
added on the other side and the conduct is perfectly closed. Afterwards, AISI H13 is added until ®
the
upper surface of the desired geometry is reached. These last strategies have been programmed with.
desired geometry is reached. These last strategies have been programmed with NX11 from Siemens
upper
Zig/Zag
NX11 surface
fromstrategyof the
Siemens desired
is ®followed
. Zig/Zag geometry
instrategy is
the addedis reached. These
in thelast
layers alternatively
followed strategies
added (Figure have been programmed
layers 15c,d).
alternatively (Figure 15c,d). with
NX11 from Siemens®. Zig/Zag strategy is followed in the added layers alternatively (Figure 15c,d).

Figure 15. (a) Front; (b) lateral views of the resulting part after LMD; (c) transversal LMD; (d)
15. (a)(a)Front;
Figure 15.
Figure Front;(b)(b) lateral
lateral views
views of of
thethe resulting
resulting partpart
afterafter
LMD;LMD; (c) transversal
(c) transversal LMD;LMD;
(d)
longitudinal LMD.
(d) longitudinal
longitudinal LMD. LMD.
In order to obtain a “near-to-net-shape” geometry, the layers width is reduced for upper layers
In order
In order to
to obtain
obtain aa “near-to-net-shape”
“near-to-net-shape” geometry, the
the layers width
width is
is reduced
reduced for
for upper
upper layers
layers
gradually. This way, a semi-cylinder geometrygeometry,
is created andlayers
machining times are reduced because of
gradually. This
gradually. This way,
way, aa semi-cylinder
semi-cylinder geometry is
geometry is created
created and
and machining
machining times areare reduced
reduced because
because of
a lower volume of material to be machined. The resulting near-net-shape times
part is shown in Figure 16. of
a lower volume of material to be machined. The resulting near-net-shape part is shown
a lower volume of material to be machined. The resulting near-net-shape part is shown in Figure in Figure
16.16.

Figure 16. (a) Front; (b) lateral views of the resulting part after LMD.
Figure 16. (a) Front; (b) lateral views of the resulting part after LMD.
Figure 16. (a) Front; (b) lateral views of the resulting part after LMD.
Because of the LMD process, residual stresses are generated. Annealing the specimen so that the
Because
residual
Because of
ofthe
stresses LMD
are
the LMD process,
relieved residual
residualstresses
is strongly
process, recommended.
stresses are
aregenerated. Annealing
The annealing
generated. thethe
process
Annealing specimen
isspecimenso that
a conventional the
so that
residual
treatment stresses
the residualthat are
consists
stresses relieved
areofrelievedis strongly
keepingisthe recommended.
samplerecommended.
strongly The
at 650 °C for a holding annealing process
time ofprocess
The annealing is
two hours, a conventional
slow cooling
is a conventional
treatment
to 500 °C that
treatment and consists
that of
of keeping
free cooling
consists in air.the
keeping sample
The
the part at
sample at 650
is °C
◦ C for
for aa holding
consequently
650 milledtime
holding andof
time two
two hours,
hardened
of hours, slow
before cooling
slowthe last
cooling
to 500 ◦°C
finishing and
to 500 C milling free cooling
and freeoperation, in
cooling inaiming air. The
air. Thetopart part
attain is consequently
a higher hardness
is consequently milled
milledwhen and hardened
finished. The
and hardened before
hardening
before the last
consists
the last finishing
finishing
of heating
milling milling operation,
the partaiming
operation, at 1050to aiming
°Cattain to
for 15a min attain
and
higher a higher hardness
then quenching
hardness when
in water.
when finished. finished. The hardening consists
The hardening consists of heating
of heating
The the
final part
◦ at
specimen 1050 is °C for
then 15 min
subjected and to
the part at 1050 C for 15 min and then quenching in water. then
a quenching
non-destructive in water.
test via X-ray radiography, X-Cube
The
compact final
The 225 specimen
final(General is
specimenElectric, then subjected
Boston, MA,
is then subjected to a non-destructive
to aUSA), in order to
non-destructive test via
via X-ray
verify
test radiography,
its internal
X-ray X-Cube
structure
radiography, and
X-Cube
compact
integrity.
compact The225 (General
225 results
(General Electric,
areElectric, Boston,
shown inBoston, MA,
Figure MA, USA),
17b, where
USA),the in order
in geometry to verify its internal
of the internal
order to verify cooling
its internal structure
channel
structure and
andis
integrity.
also The
The results are shown in Figure 17b, where the geometry of the internal cooling channel is
appreciated.
integrity. results are shown in Figure 17b, where the geometry of the internal cooling channel is
also appreciated.
also appreciated.
Metals 2018, 8, x102
2018, 8, FOR PEER REVIEW 13 of 15
Metals 2018, 8, x FOR PEER REVIEW 13 of 15

Figure 17. (a) Final part; (b) X-ray inspection.

Figure 17. (a) Final part; (b) X-ray inspection.
Figure 17. (a) Final part; (b) X-ray inspection.
3.5. Conformal Cooling via Thermal Simulations
3.5. Conformal Cooling via Thermal Simulations
With the aim
3.5. Conformal of demonstrating
Cooling the thermal benefits of conformal cooling, a comparison between
via Thermal Simulations
the new
Withadaptive
the aim ofchannel and the conventionally
demonstrating straight
the thermal benefits channel iscooling,
of conformal realizeda by means ofbetween
comparison thermal
With
simulations.the aim of demonstrating
An analysis the thermal benefits of conformal cooling, a comparison between
the new adaptive channelofand thethe
performance of both
conventionally typeschannel
straight of cooling ducts isby
is realized shown
means in of
Figure 18,
thermal
the
wherenew adaptive
the hotAn channel and
stamping themetal
conventionally straight channel is realized by means of thermal
simulations. analysisofofa the
sheet blankofis both
performance simulated.
types of cooling ducts is shown in Figure 18,
simulations.
Atthe
thehot An analysis
initial time step of the performance to of both typesthe
of bulk
cooling ducts is shown
is of 20in°C
Figure 18,
where stamping of a and
sheetaccording
metal blank the process,
is simulated. temperature and the
where
heated the hotsheet
stamping of a °C.
sheet metal blank is simulated.after 5 s are displayed.
At metal is at step
the initial time 900 andTemperature
according todistributions
the process, the bulk temperature is of 20 °C and the
heated metal sheet is at 900 °C. Temperature distributions after 5 s are displayed.

Figure 18. Thermal simulation results of conventional drilled (a) vs. conformal (b) cooling.
Figure 18. Thermal simulation results of conventional drilled (a) vs. conformal (b) cooling.
Figure 18. Thermal simulation results of conventional drilled (a) vs. conformal (b) cooling.
As expected, the temperature distribution of the conformal part is more homogeneous than in
At the initial time step and according to the process, the bulk temperature is of 20 ◦ C and the
the drilled
Asmetal specimen,
expected, following thedistribution
geometry of of the conformal
channel. Moreover, at the same time instant,
heated sheetthe
is attemperature
900 ◦ C. Temperature distributions after 5 spart
are is more
displayed. homogeneous than in
lower
the temperatures
drilled specimen, are reached.the
following This may imply
geometry of a higher
the channel.cooling rate of
Moreover, at the
the conformal
same time channel.
instant,
As expected, the temperature distribution of the conformal part is more homogeneous than in the
Therefore,
lower additivelyare
temperatures built up cooling
reached. channels
This may imply present the cooling
a higher same performance
rate of the as drilled channels,
conformal channel.
drilled specimen, following the geometry of the channel. Moreover, at the same time instant, lower
when they additively
Therefore, have the very
builtsame geometry.
up cooling However,
channels thethe
present main benefit
same of conformal
performance channels
as drilled is the
channels,
temperatures are reached. This may imply a higher cooling rate of the conformal channel. Therefore,
possibility
when they of adapting
have the very to more
same complex
geometry. cooling system
However, designs
the main and their
benefit of constant
conformal distance to the
channels is die
the
additively built up cooling channels present the same performance as drilled channels, when they
surface. of adapting to more complex cooling system designs and their constant distance to the die
possibility
have the very same geometry. However, the main benefit of conformal channels is the possibility of
surface.
adapting to more complex cooling system designs and their constant distance to the die surface.
4. Discussion
4. Discussion
In the present work, the design and manufacturing of conformal cooling ducts via additive
manufacturing
In the presentis investigated.
work, the design Theirandmechanical performance
manufacturing and heat
of conformal transfer
cooling ductscapability are
via additive
manufacturing is investigated. Their mechanical performance and heat transfer capability are
Metals 2018, 8, 102 14 of 15

4. Discussion
In the present work, the design and manufacturing of conformal cooling ducts via additive
manufacturing is investigated. Their mechanical performance and heat transfer capability are
evaluated, both experimentally and by thermal simulations. According to the obtained results,
the following conclusions can be drawn:

(1) In general terms, it can be concluded that the strategy of generating cooling channels via LMD is
a viable alternative to traditional techniques regarding the metallurgical quality and mechanical
and thermal characteristics achieved on the manufactured die. Previous experiments performed
with this approach demonstrate the attainability of minimum channel diameters of down to
3 mm and minimum wall thicknesses of 2 mm.
(2) With regard to thermal characteristics, a more homogeneous temperature distribution within the
tool and the stamped part is attained, leading to the enhancement of the dimensional accuracy
and features of the produced parts. Moreover, the betterment of the temperature distribution also
leads to the lowering of the process cycle times in hot stamping and the subsequent improvement
of the efficiency of the process and reduction of the costs.
(3) Apart from meeting the mechanical requirements demanded by the hot stamping process,
the built-up channel is smooth and without projected material, leading to a good internal quality.
In addition, the lack of pre and post heating cycles during the LMD process together with the
absence of inserts for the generation of the channel ease the process as far as industrialization
issues are concerned.

Hence, this work demonstrated the capability of achieving good mechanical and thermal
properties for additively manufactured conformal cooling hot stamping dies. Therefore, the advances
in LMD processes open doors for new designs, which may enable the generation of more complex
geometries and hence innovate towards the manufacturing of new parts.

Acknowledgments: This study was supported by the H2020-FoF13 PARADDISE Project (Grant Agreement
No. 723440) and the ADDICLEAN Project (RTC-2015-4194-5) of the Spanish Ministry of Economy and
Competitiveness and the University of the Basque Country (UPV/EHU). Special thanks are addressed to Batz S.
Coop. Company (Igorre, Spain) for their technical support in this work.
Author Contributions: Jon Iñaki Arrizubieta and Magdalena Cortina conceived and designed the experiments;
Jon Iñaki Arrizubieta, Magdalena Cortina and Amaia Calleja performed the experiments; Jon Iñaki Arrizubieta
realized the thermal simulations and Magdalena Cortina analyzed the data; Eneko Ukar and Amaia Alberdi
contributed materials/analysis tools; Magdalena Cortina wrote the paper.
Conflicts of Interest: The authors declare no conflict of interest.

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