Laser Powder Bed Fusion Tool Repair: Statistical Analysis of 1.2343/H11 Tool Steel Process Parameters and Microstructural Analysis of the Repair Interface

Megahed, Sandra; Koch, Raphael; Schleifenbaum, Johannes Henrich

doi:10.3390/jmmp6060139

Cited by 7 publications

(2 citation statements)

References 28 publications

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“…Carbide formers in the investigated H11 (1.2343) steel are Mo, Cr and V. Chrome-molybdenum steels like H11 are manufacturable by PBF-LB/M using a preheated platform, not only to decrease thermal stress, but also to minimize the amount of retained austenite [8]. If manufactured without a pre-heated platform, the processing window is very narrow [9]. Other possibilities of minimizing the amount of RA are adapted alloy compositions or AM processes with lower cooling rates such as (HS) DED.…”

Section: Introductionmentioning

confidence: 99%

Rapid Alloy Development Using Calphad Simulation and Powder Blends in Direct Energy Deposition

Bold,

Raffeis,

Adjei-Kyeremeh

et al. 2024

Metals

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The ongoing commercialization of additive manufacturing (AM) has necessitated the need to tailor alloy chemistry as well as exploit AM process particularities such as freedom of design, print geometry and high cooling rates to meet functional application requirements. Alloys such as hot-work tool steels, including H11, are well suited for machining and tooling applications. In this work, the authors investigated and compared high-speed direct energy deposition with laser beam source (HS DED-LB/M) processability of a reference H11 alloy and its modified form (H11m). The modification of the alloy was intended to minimize the amount of retained austenite (RA) in as-built microstructure and reduce post-heat treatment steps. The investigative approach included Calphad simulation, rapid alloy blending (modified powder) and process parameter optimization to produce dense parts for microstructure characterization and mechanical properties testing. The results show that while H11 achieved a high relative density > 99.85%, H11m still had cracks parallel to the building direction. The amount of RA was equally reduced from 4.08% in H11 to 1.23% in the H11m. H11 had a comparatively superior average microhardness (591 HV0.5) to H11m (561.5 HV0.5), which can be attributed to the more carbide presence. The martensitic strengthening effect between H11 and H11m can be described as similar.

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Section: Introductionmentioning

confidence: 99%

Rapid Alloy Development Using Calphad Simulation and Powder Blends in Direct Energy Deposition

Bold,

Raffeis,

Adjei-Kyeremeh

et al. 2024

Metals

Self Cite

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“…Various methods are used to evaluate the lifetime and wear of the moulds. These include light and electron microscopy for microstructure and defect evaluation, surface roughness and hardness measurements or tribometers for wear assessment [12][13][14].…”

Section: Introductionmentioning

confidence: 99%

Introduction to the Methodology of the Study of Operational Wear of Experimental Shaped Parts of Moulds for HPDC of Zinc Alloys

KOZA,

GRYC,

SOCHA

et al. 2023

METAL Conference Proeedings

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This research article introduces a methodology for studying the operational wear of experimental shaped parts of moulds for high-pressure die casting (HPDC) of zinc alloys. The study includes roughness analysis and geometric dimensioning and tolerancing (GD&T) based on a coordinate measuring machine (CMM) and 3D scanning to quantify the wear of the mould parts due to contact with the zinc alloy melt and solidifying castings during the HPDC process cycles. The research aims to improve the understanding of the mechanisms of mould wear in HPDC of zinc alloys if different types of steel grades and their production technologies are applied during a hundred thousand casting cycles. The results show roughness and geometrical changes on the surface of shaped parts of moulds made from H11 steel grade conventionally, respectively additively manufactured by selective laser melting (SLM).The results so far have shown that the shaped parts of the mould made of conventional H11 steel after 500,000 or additively manufactured H11 steels show the good shape and surface stability after 100,000 casting cycles. Until now, it has not been possible to determine the negative effect of the given HPDC process on the wear of the studied shape parts of the moulds using the above methods; the analyses will continue until their final wear. In parallel with evaluating the shape and surface of the shaped parts, these parameters are also assessed for the zinc alloy castings. However, the evaluation can't be squeezed into the required scope of this contribution. In the following research phase, also metallographic methods will be applied to study the quality parameters of both shaped mould inserts (after their wear) and castings (after different numbers of casting cycles) too. The final and tested methodology, in connection with other extensive outputs of the research and development carried out within the framework of the solved project, should be helpful for designers and manufacturers of shaped parts of moulds and for the own HPDC of zinc alloys.

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An overview of strategies for identifying manufacturing process window through design of experiments and machine learning techniques while considering the uncertainty associated with

Cabrera,

Zouhri,

Zimmer-Chevret

et al. 2024

Int J Adv Manuf Technol

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Laser Powder Bed Fusion Tool Repair: Statistical Analysis of 1.2343/H11 Tool Steel Process Parameters and Microstructural Analysis of the Repair Interface

Cited by 7 publications

References 28 publications

Rapid Alloy Development Using Calphad Simulation and Powder Blends in Direct Energy Deposition

Rapid Alloy Development Using Calphad Simulation and Powder Blends in Direct Energy Deposition

Introduction to the Methodology of the Study of Operational Wear of Experimental Shaped Parts of Moulds for HPDC of Zinc Alloys

An overview of strategies for identifying manufacturing process window through design of experiments and machine learning techniques while considering the uncertainty associated with

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