Abstract
Selective laser melting (SLM) and metallic injection moulding (MIM) are established processes for the production of high-performance metallic components for small and large series. In the aerospace industry, where very high demands are placed on materials and components, both processes are still considered to be relatively new. In both processes, the conventional titanium alloy Ti-6Al-4V can be used in the form of powder. Currently, both technologies are only considered separately. By fusing components of the same type, multifunctional components with a high lightweight construction potential can be produced.
 In order to generate direct material fusion, the MIM component must be mechanically processed accordingly. In addition, suitable SLM process parameters must be developed in order to ensure both generative construction and high joint strength. To this end, a characterisation of the joining zone and the static joint strength was carried out. Furthermore, pressure test samples were designed and examined both statically and for fatigue strength. Thus, a high static joint strength could be proven. The compression test samples also withstood a fatigue strength of over 1 million cycles.
Highlights
The production of cost-effective metallic system components, especially for aerospace applications, is to be achieved by future hybrid manufacturing processes
3.1 metallic injection moulding (MIM) subcomponent The density of the material batches for PM300 + PM400 was 98.3 %, the tensile strength was 920MPa
The elongation at break is more than 10 %, which corresponds to the target value for MIM parts made of Ti-6Al-4V
Summary
The production of cost-effective metallic system components, especially for aerospace applications, is to be achieved by future hybrid manufacturing processes. In this context, the key technologies of selective laser melting (SLM) and metal injection moulding (MIM) have emerged. Selective laser melting is characterised by the production of near-net-shape and geometrically complex components with high functional density. The use of titanium alloys, such as Ti-6Al-4V, is known in both technologies from the state of the art [1,2,3,4,5] It is characterised by e.g. high specific strength, corrosion resistance, low density and good weldability. By using individual components from the MIM and SLM processes
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