OBRABOTKAMETALLOV Vol. 28 No. 2 2026 29 TECHNOLOGY References 1. Kelliger T., Meurer M., Bergs T. Potentials of additive manufacturing for cutting tools: a review of scientifi c and industrial applications. Metals, 2024, vol. 14 (9), p. 982. DOI: 10.3390/met14090982. Dependence of gas porosity in a metal-polymer composite on residual pressure during vibro-vacuum degassing for metal-composite tool bodies Nikolay Lubimyi a, Andrey Polshin b, Boris Chetverikov c, *, Vladislav Prokopenko d, Ardalion Maltsev e, Mikhail Bytsenko f Belgorod State Technological University named after V.G. Shukhov, 46 Kostyukova St., Belgorod, 308012, Russian Federation a https://orcid.org/0000-0002-6131-3217, nslubim@bk.ru; b https://orcid.org/0000-0001-5809-4458, info@polshin.ru; c https://orcid.org/0000-0003-1801-6767, await_rescue@mail.ru; d https://orcid.org/0000-0002-7120-1411, vlad.prokopenko1@yandex.ru; e https://orcid.org/0000-0002-0878-3658, ardalion_bgtu@mail.ru; f https://orcid.org/0009-0004-2133-885X, b.michutka2005@gmail.com Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2026 vol. 28 no. 2 pp. 6–31 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2026-28.2-6-31 ART I CLE I NFO Article history: Received: 02 February 2026 Revised: 12 February 2026 Accepted: 14 March 2026 Available online: 15 June 2026 Keywords: Metal–composite technology Metal–polymer composite material Vibro-vacuum degassing Gas porosity SLM shell Funding This study was supported by grant No. 23-79-10022 from the Russian Science Foundation, https://rscf.ru/ project/23-79-10022/. Acknowledgements The study was performed using the facilities of the High Technologies Center of Belgorod State Technological University named after V.G. Shukhov. ABSTRACT Introduction. The metal–composite technology (MCT) for manufacturing tool bodies using an “SLM shell + metal–polymer composite material (Metal–polymer/MPCM)” enables the implementation of curvilinear coolant/lubricant supply channels and reduces the additively manufactured metal volume; however, the quality of fi lling thin-walled cavities is critically determined by the level of gas porosity of the fi ller. Gas porosity degrades the thermal conductivity and load-bearing capacity of the MPCM, reduces the stability of fi lling in critical zones near the SLM shell wall and adjacent to the channels, and increases properties dispersion and the risk of defects during tool operation. The purpose of the work is to experimentally establish the relationship between MPCM gas porosity and residual pressure under vibro-vacuum degassing and to justify a technologically preferable vacuum range for application in MCT tool bodies. Methodology. The study was carried out using a vibro-vacuum setup comprising a preliminary degassing chamber and a casting chamber with low-frequency vibration. Standard MPCM samples were produced for each vacuum condition. Porosity was evaluated using an adopted scoring scale based on microscopy (analysis of pore distribution, clustering, and characteristic defect sizes). Results and discussion. The experiment revealed a stable nonlinear (V-shaped) trend: as pressure decreases from atmospheric to approximately 450 Pa, the average porosity score monotonically decreases and reaches a minimum in the 400–350 Pa range (1–2 points). Further vacuum intensifi cation below 300 Pa leads to vigorous gas evolution and foaming (“boiling”), accompanied by a sharp increase in defectiveness (up to 3–5 points). Conclusions. The identifi ed optimal vacuum range of 400–350 Pa is recommended as a compromise between eff ective removal of entrapped gas and avoidance of the foaming, ensuring reproducible fi lling quality of MPCM within SLM shells in MCT tool-bodies manufacturing. For citation: Lubimyi N.S., Polshin A.A., Chetverikov B.S., Prokopenko V.S., Maltsev A.K., Bytsenko M.V. Dependence of gas porosity in a metal-polymer composite on residual pressure during vibro-vacuum degassing for metal-composite tool bodies. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2026, vol. 28, no. 2, pp. 6–31. DOI: 10.17212/1994-63092026-28.2-6-31. (In Russian). ______ * Corresponding author Chetverikov Boris S., Ph.D. (Engineering), Associate Professor Belgorod State Technological University named after V.G. Shukhov, 46 Kostyukova St., 308012, Belgorod, Russian Federation Tel.: +7 951 134-32-43, e-mail: await_rescue@mail.ru
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