Manufacturing a prototype with laser direct metal deposition and laser welding made from martensitic steel 1.4313

Abstract Burckhardt Compression Holding AG, based in Winterthur, is an internationally active manufacturer of reciprocating compressors who uses three-piece pistons its Laby® compressors. Due to their design for casting, the have a high weight, which limits size piston, particularly large diameters. For this reason, solutions are being looked produce lightweight using metal additive manufacturing processes counteract these challenges. One innovative techniques weight reduction that has been applied various fields science and industry laser direct deposition (DMD). Therefore, project was started with reduce mass enabling higher operating speeds. This study presents workflow manufacture piston from martensitic steel 1.4313 by (DMD) diameter approximately 342 mm height 140 mm. The characterized different segments, conventionally additively manufactured overcome machine limitations. crown joined part sealed CO 2 welding. Reducing power DMD reduced temperature, hence, oxidation manganese silicium reducing carrier gas flow improved buildup rate turbulence induced oxidation. Alternating feed direction per layer geometrical accuracy avoided material accumulation at sharp corners. A method found indicate quantitatively radius direction. welding types seams were selected enable good force flow; however, clamping device necessary. double weld strategy considered order notch effect hidden T-joints. enabled 40% resulting 24 kg compared cast 40 kg. Metallographic analysis 3D scans performed evaluate quality accuracy. shows limitations challenges how segmentation.