Single Point Incremental Forming (SPIF) is an unconventional forming process that is suitable for prototype production and small lot production due to the economical tooling cost, short lead time, and the ability to create symmetrical and asymmetrical complex geometries without the use of expensive dies. This article presents the effect of the step size Δz of a forming tool made of 145Cr6 tool steel on the formability and maximum forming angle, mechanical properties, hardness, surface roughness, microstructure and texture of bimetallic Al/Cu sheets. Experiments were conducted at a constant rotational speed and feed rate, with the use of rapeseed oil as a lubricant. The tests were carried out with the use of a forming tool on both sides of the bimetallic sheet. The shape and dimensions of the formed elements are determined by non-contact optical 3D scanning. It has been proved that an increase in the step size Δz affects the deterioration of the surface quality of the specimens (an increase in the Ra parameter from 0.2 μm to approximately 3 μm for the step size of 1.2 mm), while a small step size down Δz favours the geometric stability of the samples. With increasing step size (at Δx = Δy = const.), the drawpiece wall continually thinned until the material fractured. Based on the results, it was shown that increasing the step size Δz over 1.1 mm causes cracking of the drawpieces. Furthermore, greater thinning of the Al/Cu sheet was observed in the range of step size Δz between 0.7 and 1.0 mm for aluminum side and step size Δz ≤ 0.6 mm and Δz ≥ 1.1 mm for copper side. It was also found that the mechanical properties of the bimetal sheet decreased as a result of incremental forming. The greatest decrease in strength and ductility was recorded for a pitch of 1.2 mm. Strength decreased from 230 MPa (for sheet in initial state) to approximately 80 MPa, elongation from 12% to approximately 8.5%, and hardness from 120 HV10 for Cu and 60 HV10 for Al to approximately 30 HV10 for both layers.

An EN AW-6082 aluminium alloy is one of the 6000 series aluminium alloys with the highest strength properties. Due to its favourable strength-to-density ratio, it is used, among others, in the automotive and aviation applications. It is also characterised by good formability, especially in the annealed condition. This article presents the results of investigations on the possibility of forming a 2 mm thick EN AW-6082 alloy sheet using the incremental sheet-forming process depending on the material condition (O, W, T4, T6). The microstructure of the material after heat treatment and the mechanical properties of the workpiece material in as-received state, as well as after forming, were examined. Additionally, for selected cases, additional heat treatment of the drawpieces was performed to improve their mechanical strength. The values of the limit-forming angle were determined for the materials tested. The values of this angle varied from 69° for the annealed sheet to 61° for the material in the T6 condition. The highest yield stress (YS) and ultimate tensile strength (UTS) were found for sheets (YS = 305 MPs and UTS = 324 MPa) and the artificially aged drawpieces (YS = 333 MPa and UTS = 390 MPa). Additional ageing after incremental sheet forming resulted in an increase in strength properties compared to drawpieces without additional heat treatment only in the case of drawpieces made of sheet metal after the solutionising and in T4 condition.

This article assesses the tribological performance of new composite tool sets for stamping dies. Four sets of composite countersamples were tested. These consisted of polyurethane resin with mineral filler (base variant) and modified with aluminium powder (10wt%) and roving fabric (5wt%). Strip samples for the strip drawing tests were cut from AMS5599 (Inconel 625) corrosion-resistant nickel alloy, AMS5510 (321) corrosion and heat-resistant steel and AMS6061-T4 heat treatable aluminium alloy sheet metals. The influence of the type of sample material on the coefficient of friction (COF) was observed. The smallest values of the COF over the entire range of clamping force values used on AMS5599 and AMS5510 sheets were observed during tests with countersamples made of the base variant of composite. When testing the AMS6061-T4 aluminium alloy sheet, the countersamples modified with roving fabric provided the lowest value of COF, which stabilised at a value of about 0.197 as pressure was increased.

The purpose of this study was to investigate the influence of synthesis parameters and surface finish on the corrosion of DMLS-printed M300 steel components and to evaluate their applicability in corrosive environments. In order to assess the influence of the corrosive environment, potentiodynamic and long-term corrosion tests were carried out in this study, together with microscopic and EDS studies on 3D-printed M300 steel samples synthetized using the DMLS method with different laser powers. The results show that DMLS-produced M300 steel is vulnerable to corrosion in corrosive environments. The effect of the laser power used on the corrosion resistance was also demonstrated, which generally decreases with increasing laser power. This study confirms the influence of the surface condition of the components on the corrosion phenomenon. Despite the higher corrosion resistance of unpolished components, they lose mass to a higher degree in a corrosive environment. This study also shows the influence of temperature on the corrosion phenomena occurring, demonstrating its negative effect. This study also presents the microstructure of the surface of the samples after the tests, showing the degradation of the surface due to corrosive actions. The analysis of the test results suggests the protection of M300 steel components produced using the DMLS method for the case of operation in corrosive environments.

This paper presents the results of a pilot application of Powder-Bed Fusion of Metals Using a Laser (PBF-LB/M) for the fabrication of M300 (1.2709) maraging steel sheet metal bending tools. S235 steel was used as a substrate for the fabrication of bending punches. The main goal of the research was to determine the usability of such tools without heat treatment, which would contribute to the increase in the cost of tool production. Industrial tests of tools were conducted during the forming of Inconel 625 and AW-6061 T0 aluminium alloy sheets. The punches were subjected to tests of surface roughness, hardness, microstructure, porosity, and geometric quality in order to verify the quality and accuracy of tools made by the PBF-LB/M technique before and after experimental investigations in industrial conditions in a selected manufacturing company. It was found that tools with an M300 steel working layer after the PBF-LB/M process without heat treatment show suitability for bending sheet metal in a certain range of force parameters, ensuring obtaining elements after bending from Inconel 625 and AW-6061 T0 aluminium alloy sheets of the required geometric quality.

The paper presents the numerical and experimental results of research aimed at determining the influence of hardness in the range of 50–90 Shore A of layered tools composed of elastomeric materials on the possibility of forming Inconel 625 nickel-based alloy sheets. A stamping die composed of 90MnCrV8 steel (hardness 60HRC) was designed for forming embosses in drawpieces, ensuring various stress states on the cross-section of the formed element. The principle of operating the stamping die was based on the Guerin method. The finite-element-based numerical modelling of the forming process for various configurations of polyurethane inserts was also carried out. The drawpieces obtained through sheet forming were subjected to geometry tests using optical 3D scanning. The results confirmed that, in the case of forming difficult-to-deform Inconel 625 Ni-based alloy sheets, the hardness of the polyurethane inserts significantly affected the geometric quality of the obtained drawpieces. The assumptions determined in numerical simulations were verified in experimental studies. Based on the test results, it was concluded that the selection of polyurethane hardness should be determined by the shape of the formed element. Significant nonuniform sheet metal deformations were also found, which may pose a problem in the process of designing forming tools and the technology of the plastic forming of Inconel 625 Ni-based alloy sheets.