Cladding of a forming insert for the white goods industry

Challenge

Manufacturing and maintaining forming inserts for high-demand surface applications comes with several inherent challenges:

• High material costs: These inserts typically require expensive, wear-resistant alloys to meet durability and surface quality standards.
• Long lead times: Manufacturing complex inserts from solid blocks of metal is time-intensive.
• Costly maintenance downtime: Surface wear on inserts can halt production. Traditional repair methods are slow and often involve reworking or replacing the entire insert, further extending downtime.

To remain competitive, Gorenje Orodjarna sought a solution that could reduce lead times and costs, without sacrificing tool performance or quality.

Solution

Automated repair provides a more efficient and sustainable approach by depositing material only where it was functionally required, optimizing both cost and performance.

• Smart material strategy: A cost-effective hybrid approach was adopted: a standard AMPCO aluminium-bronze alloy was selectively deposited as the functional layer, while a more economical base material formed the structural core. This reduced material waste and overall cost without compromising performance.
• Targeted design: The structural core was intentionally designed with buffer zones: less material in high-wear areas. This allowed for greater deposition of aluminium-bronze where it is most needed. This design strategy ensured optimal reinforcement without overbuilding the entire part.
• Precision finishing: Final finishing was achieved through fine milling and manual polishing, meeting the strict surface and dimensional tolerances required for reliable operation.

This approach successfully demonstrated MaxQ Repair’s potential for manufacturing complex, high-performance tooling surfaces using specialized alloys, while improving efficiency and sustainability.

Result

The implementation of MaxQ Repair delivered measurable benefits across performance, cost, and sustainability:

• Reduced maintenance lead time: By enabling faster and more targeted repairs, MaxQ Repair significantly cut tool downtime, allowing for quicker return to production.
• Equivalent tool performance:The WAAM-produced insert demonstrated functionality and durability on par with traditionally manufactured counterparts, successfully passing all performance tests conducted to date.
• Efficient material utilization: Through selective deposition, the process used 86% less material compared to conventional manufacturing methods, substantially lowering material costs and waste.
• Environmental impact reduction: WAAM led to a 41% to 84% decrease in CO₂ equivalent emissions. According to the ReCiPe2016 life cycle assessment method, it also outperformed traditional manufacturing in 17 out of 18 environmental impact categories, reinforcing its sustainability advantages.