Experimental Investigation on the Forming of Additively Manufactured Components with Regard to Forming Behavior and Component Properties

Additive Manufacturing is an established process group that includes various technologies. In contrast to subtractive methods, complex components can be produced by applying layers of construction materials. In accordance with the standard VDI Guideline 3405, additive manufacturing technologies can be differentiated into wire- and powder-based technologies. The basis for these experimental investigations is a Wire Arc Additive Manufacturing (WAAM) process with a high build-up rate (Cold Metal Transfer - CMT) to produce a rectangular thin-walled component made of G4Si1 (1.5130). In order to analyze the influence of a subsequent forming process on the microstructural properties and the forming behavior of the components, compression tests were carried out. Therefore, cylindrical specimens were made out of the additively manufactured components by machining. To be able to take a possible anisotropy in the workpiece caused by the multi-layer welding into account, the samples were taken both along and across the welding direction. To evaluate the inhomogeneous component properties, cast specimens with a representative microstructure were produced by inductive melting of the filler material and subsequent a solidification with an appropriate cooling rate. In addition to the cold forming of the additively manufactured components, the investigation also includes hot forming and the influence of a corresponding heat treatment. The experimental examination was completed by the analysis of the microstructure of each material state. The aim of the research work was to prove the homogenization and optimization of the mechanical properties of additive manufactured components due to a subsequent forming process.