Dievar and 3D printing

Together with VŠB-TUO Ostrava (Technical University Ostrava) and Galvamet, we set out to verify the necessary technology for printing inserts of die casting dies according to Nadca 207. There were many doubts, especially regarding the use of HIP. Both Uddeholm and Voestalpine gave vague answers to my questions.

However, our conviction, together with doc. Ing. Tomášem Čeganem, Ph.D from VŠB, was unequivocal. Without HIP, this is not the way forward for industrial use. Why this opinion? Because even though we have several NDT tests, we cannot see completely inside the material. And therefore, we do not see potential hidden defects that can significantly reduce the service life of the final part.

And because 3D printed parts in high-pressure die casting (HPDC) are critical parts, just like critical parts of aircraft engines, these parts must also pass HIP. And because according to the Commercial Code, we guarantee quality for hidden defects for a period of 2 years, manufacturers of tools, or die inserts made by the 3D printing method, risk having to pay all costs from the unsuccessful application of parts made by 3D printing if they do not follow standard procedures during its production.

And what is the result of our research? Although we are still before the final tests, the interim results confirm our path.

The metallography of the samples printed on the Renishaw AM500E printer are in the following picture (Fig. 1) and are intentionally attached to the permitted structures according to Nadca 207:2024. The samples were printed as coupons according to the Nadca 207 specification (Fig. 2), then annealed to remove stress in a vacuum furnace and cut from the printing platform. HIP was then applied, and the heat treatment consists of gas stream quenching and triple tempering.

Fig. 1 – Metallography of the sample structure after 3D printing, HIP and heat treatment

Fig. 2 – Coupons after printing ready for stress relief annealing

In order to measure the cooling rate and also adapt the testing to the real conditions of future printed inserts, the test coupons were hardened between two plates, each weighing approximately 30 kg (Fig. 3). The thermocouple Ts was placed in the load plate, the thermocouple Tc in the coupon. The cooling rate from the austenitization temperature to 540 °C was approximately 12 °C/min on Ts and Tc, i.e. more than double the prescribed 28 C/min according to Nadca-207.

Fig. 3 – Assembly of coupons for hardening including placement of thermocouples Ts and Tc

The resulting structure is more than optimistic. Virtually none of the listed permitted structures after hardening according to Nadca 207 has such amazing fine-grained and uniformity as the samples after applying our procedure. The same is true of the impact test results. Values >40 J significantly exceed all values for wrought steels according to Nadca 207.

However, since this is still a process parameter testing, without practical results, we will only move in theory. So, if you have your own critical inserts or want to test 3D printing with comfortable cooling, we are ready. Our only limitation so far is the HIP and its dimensions, diameter 152 x 300 mm, but in cooperation we can move to all sizes from the 250 x 250 mm printing platform.

And what are the parameters of HIP and heat treatment. So, it remains the intellectual property of VŠB-TUO Ostrava and Galvamet Vsetín. If you are interested in cooperation, please contact

Ing. Zbyněk Slavík
Sales department
Tel: +420 571 999 973
Mobil: +420 724 375 922
Email: slavik@galvamet.cz

Jiří Stanislav

March 16,  2025