Hot Work Tool Steel Processed by Laser Powder Bed Fusion: A Review on Most Relevant Influencing Factors

Wu, Liang; Das, Suchandrima; Gridin, Witalij; Leuders, Stefan; Kahlert, Moritz; Vollmer, Malte; Niendorf, Т.

doi:10.1002/adem.202100049

Cited by 28 publications

(15 citation statements)

References 48 publications

(86 reference statements)

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“…Maybe that is one reason why there is only one study [15] investigating the properties of PBF-EB H13 parts in the last years, instead of countless articles, which were summarized by [16] about processing H13 via PBF-LB. Although H13 shows various challenges in terms of cracking during PBF-LB which were shown in detail by [17].…”

Section: 𝑞̇ = 𝛼 • ∆𝜗 𝑙𝑛mentioning

confidence: 98%

Tailoring flow behavior and heat transfer in tempering channels for high pressure die casting – Analysis of potentials of commercial static mixers and prospects of additive manufacturing

Sode¹,

Kahlert²,

Arold³

et al. 2022

Preprint

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High Pressure Die Casting (HPDC) is an economic manufacturing processes for production of complex, multifunctional and thin-walled metal components with near-net-shape geometries. During die filling and subsequent solidification of the component in the die, efficient and robust control of temperature is of utmost importance. This is mostly achieved by fluid-based temperature control systems. Eventually, the heat transfer between the fluid and the die determines total cycle times. In present work the impact of static mixers and most relevant processing conditions is investigated experimentally as well by Computational Fluid Dynamics (CFD) simulation. Static mixer elements are integrated into straight tempering channels to stimulate turbulences of the flowing tempering medium and, eventually, increase the heat transfer coefficient α. In a second step, prospects related to additive manufacturing (AM) of moulds by means of Laser Powder Bed Fusion (PBF-LB) are detailed and discussed. The unprecedented design freedom of AM opens up numerous possibilities for positioning the static mixer elements, as highlighted for helical mixers in tempering channels of HPDC die casting moulds made of AISI H13 (X40CrMoV5-1, 1.2344). Obviously, in recent years AM already has been exploited to establish near-contour temperature control systems in industrial applications, i.e., for conformal cooling. However, the flow-influencing mixing elements investigated in the present work have not been considered so far. As will be highlighted by the results presented, a positive impact on heat transfer and, thus, further increase in terms of the economic efficiency of the HPDC process arises from the concepts introduced.

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Section: 𝑞̇ = 𝛼 • ∆𝜗 𝑙𝑛mentioning

confidence: 98%

Tailoring flow behavior and heat transfer in tempering channels for high pressure die casting – Analysis of potentials of commercial static mixers and prospects of additive manufacturing

Sode¹,

Kahlert²,

Arold³

et al. 2022

Preprint

Self Cite

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“…High-performance tool steels with emphasis on high hardness often contain high amounts of carbon (≥0.4 wt%), resulting in a poor weldability due to the increased hot cracking sensitivity. The PBF-LB processing of high-carbon steels with industrial standard PBF-LB systems and preheating temperatures of 200 • C or less thus often leads to cracking issues due to the high local stresses associated with the volumetric change during phase transformation as well as the repetitive heating and cooling cycles [7][8][9][10][11].…”

Section: High-performance Tool Steels For Pbf-lbmentioning

confidence: 99%

Dual-Laser PBF-LB Processing of a High-Performance Maraging Tool Steel FeNiCoMoVTiAl

et al. 2021

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As part of an international research project (HiPTSLAM), the development and holistic processing of high-performance tool steels for AM is a promising topic regarding the acceptance of the laser powder bed fusion (PBF-LB) technology for functionally optimized die, forming and cutting tools. In a previous work, the newly developed maraging tool steel FeNiCoMoVTiAl was qualified to be processed by laser powder bed fusion (PBF-LB) with a material density of more than 99.9% using a suitable parameter set. To exploit further optimization potential, the influence of dual-laser processing strategies on the material structure and the resulting mechanical properties was investigated. After an initial calibration procedure, the build data were modified so that both lasers could be aligned to the same scanning track with a defined offset. A variation of the laser-based post-heating parameters enabled specific in-situ modifications of the thermal gradients compared to standard single-laser scanning strategies, leading to corresponding property changes in the produced material structure. An increase in microhardness of up to 15% was thus obtained from 411 HV up to 471 HV. The results of the investigation can be used to derive cross-material optimization potential to produce functionally graded high-performance components on PBF-LB systems with synchronized multi-laser technology.

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“…Wu et al provide a comprehensive review on such research [ 15 ] and mention further significant factors influencing the residual stresses and crack formation. They also point out the strong link between such effects and the carbon content of the material.…”

Section: Introductionmentioning

confidence: 99%

“…A minimum required preheating temperature for crack prevention was found for carbon contents around 0.4 wt%. [ 15 ] It can also be noted that the building direction in combination with remaining defects significantly affects the fatigue life of the tool steel as it as shown by Pellizzari et al for H13. [ 4 ]…”

Section: Introductionmentioning

confidence: 99%

Impact of in Situ Heat Treatment Effects during Laser‐Based Powder Bed Fusion of 1.3343 High‐Speed Steel with Preheating Temperatures up to 700 °C

Moritz¹,

Schwanekamp²,

Reuber³

et al. 2023

steel research int.

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For laser‐based powder bed fusion (PBF‐LB) of high carbon steels, preheated build platforms can reduce thermal stresses and crack formation inside the generated material. Furthermore, the heat distribution during PBF‐LB is affected by laser energy input and heat transfer into the surrounding area. Depending on the preheating temperature and the thermal conditions during PBF‐LB, thermal gradients and different thermal exposure times of the manufactured layers can lead to in situ heat treatment effects. As a result, gradients in microstructures and properties are observed in the manufactured material. The effects are investigated on AISI M2 high‐speed steel (1.3343). Specimens are manufactured at platform preheating temperatures between 200 and 700 °C. Base plate and surface temperatures in the building layer are monitored by thermocouples and pyrometry. Local variations in the material microstructure and properties are determined and the effects of temperature distribution on microstructure and hardness are discussed.

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Hot Work Tool Steel Processed by Laser Powder Bed Fusion: A Review on Most Relevant Influencing Factors

Abstract: Figure 27. Influence of lack of fusion defects on the force flow during tensile tests for different sample orientations. Adapted with permission. [40] Copyright 2019, European Powder Metallurgy Association. a) Built vertical and b) built horizontal.

Cited by 28 publications

References 48 publications

Tailoring flow behavior and heat transfer in tempering channels for high pressure die casting – Analysis of potentials of commercial static mixers and prospects of additive manufacturing

Tailoring flow behavior and heat transfer in tempering channels for high pressure die casting – Analysis of potentials of commercial static mixers and prospects of additive manufacturing

Dual-Laser PBF-LB Processing of a High-Performance Maraging Tool Steel FeNiCoMoVTiAl

Impact of in Situ Heat Treatment Effects during Laser‐Based Powder Bed Fusion of 1.3343 High‐Speed Steel with Preheating Temperatures up to 700 °C

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