Bi-metal composite material for plastic injection molding tooling applications via fused filament fabrication process
Maxim L. Seleznev, Joseph D. Roy‐Mayhew
Abstract
Metal fused filament fabrication (FFF) technology uses metal powder filled plastic filaments, coupled with debinding and sintering operations, to produce metal parts. This study builds upon FFF technology, combining the technique with melt infiltration to create a structure that retains the surface hardness of tool steel while also benefiting from the thermal conductivity of copper. We observe excellent wettability of the copper to the steel, a complete filling of the as-sintered steel infill free volume, and diffusion of iron and chromium into copper. To demonstrate a practical use of the process, an injection mold with conformal channels is shaped using the technology. The bi-metal composite of steel and copper exhibited a thermal conductivity of 108 W/mK and a modulus of elasticity of 145 GPa in an as-manufactured condition.