Manufacturing of Net-Shape and Wear-Resistant Composite Components via the Combination of Additive Manufacturing and Hot Isostatic Pressing

Abstract

Abstract. Additive Manufacturing (AM) is an emerging technology with increasing importance in scientific and industrial applications. It is suitable for the manufacturing of very complex components straight from CAD data. Furthermore, it can complement powder metallurgical (PM) Hot Isostatic Pressing (HIP) when it is used to produce geometrical complex capsules, opposed to the manual fabrication by welding of sheet metal. This combined process route is highly automatable and can even be further enhanced when it is accompanied by numerical simulations in the design process of the near-net-shape capsules. Due to design optimization, there is no need to remove the capsule and it becomes an integral and functional part of the component. When the capsule is produced e.g., from wear-resistant materials, it can form a wear-resistant outer layer. This study comprises the manufacturing of net-shape and wear-resistant HIP capsules from the carbide rich cold working tool steel AISI A11 (X245VCrMo10-5-1) via Powder Bed Fusion – Electron Beam (PBF-EB). The capsules are filled with the tough Q+T steel AISI L6 (56NiCrMoV7) and densified by HIP with an integrated heat treatment. The focus is on the validation of the simulation, microstructural analysis, as well as analysis of the wear-resistance.