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Related Concept Videos

Plastic Deformations01:14

Plastic Deformations

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It is essential to understand how structural members behave under plastic deformation when the bending stress exceeds the material's yield strength. This state of deformation permanently alters the shape of the member, in contrast to the linear elastic behavior observed before yielding. The strain at any point in the member is expressed in terms of maximum strain. Notably, the neutral axis, which coincides with the centroid during elastic bending, shifts away from the centroid under plastic...
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Plastic Deformations01:19

Plastic Deformations

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Plastic deformation represents a fundamental concept in materials science, which explains the irreversible change in the shape of a material when it experiences stress beyond its elastic capability. This phenomenon is important in structural engineering, especially in designing and analyzing cantilever beams—structures that are securely fixed at one end and bear loads at the opposite end. When these beams are subjected to loads within their elastic range, they will return to their...
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Related Experiment Video

Updated: May 7, 2026

A Soft Tooling Process Chain for Injection Molding of a 3D Component with Micro Pillars
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Aluminium Injection Mould Behaviour Using Additive Manufacturing and Surface Engineering.

Marcelo José de Lima1, Jorge Luis Braz Medeiros1, José de Souza1

  • 1Campus Carreiros, Federal University of Rio Grande (FURG), Av. Itália, Km 8, Rio Grande 96203-900, RS, Brazil.

Materials (Basel, Switzerland)
|September 13, 2025
PubMed
Summary

Metal additive manufacturing using laser powder bed fusion (LPBF) creates advanced aluminium die-casting mould components. These components offer superior thermal management and durability compared to traditional methods.

Keywords:
additive manufacturingaluminium injection mouldsformed channels

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Area of Science:

  • Materials Science and Engineering
  • Manufacturing Technology
  • Tribology

Background:

  • Efficient thermal management and mould durability are crucial for aluminium die-casting.
  • Conventional machining limits cooling channel design, leading to hot spots and reduced mould lifespan.
  • Additive manufacturing offers potential for complex geometries and improved mould performance.

Purpose of the Study:

  • To evaluate metal additive manufacturing (LPBF) for aluminium die-casting mould components.
  • To compare 300-grade maraging steel inserts made by LPBF with conventional H13 tool steel.
  • To assess the impact of conformal cooling channels and surface treatments on mould performance.

Main Methods:

  • Fabrication of maraging steel mould components using laser powder bed fusion (LPBF).
  • Machining components to final dimensions and applying duplex surface treatment (plasma nitriding + CrAlN PVD coating).
  • Experimental assessment of thermal performance, dimensional stability, mechanical properties, and wear resistance.

Main Results:

  • LPBF components with optimized cooling achieved higher thermal efficiency.
  • Service life extended up to 2.6× compared to H13 inserts.
  • Significantly improved hardness profiles and wear resistance were observed.

Conclusions:

  • Additive manufacturing overcomes geometric and thermal limitations of conventional die-casting mould production.
  • Tailored surface treatments and optimized cooling design enhance mould reliability and productivity.
  • LPBF presents a viable solution for high-performance aluminium die-casting moulds.