Processing of High‐Carbon Steel by Selective Electron Beam Melting

Abstract

In addition to the production of lost moulds, additive manufacturing (AM) is increasingly used for the direct manufacture of tools, inserts, or parts thereof. Depending on the material and tool geometry, the combination of additive and conventional technologies (hybrid production) are advantageous. Commercially available AM tool inserts have their limits on the kinds of the materials that can be used. High‐carbon, particle‐reinforced, or crack‐prone materials are indispensable for many areas of tool making but so far can hardly be processed using the common laser‐based AM methods, as rapid solidification in these brittle materials results in high residual stresses, which may lead to crack formation. In contrast, selective electron beam melting (SEBM) is working under elevated temperatures of up to 1100 °C and, thus, minimizes thermal stresses. This study shows how such materials can be processed by SEBM. Results are presented for the first‐time production of high‐carbon iron–chromium alloy. Herein, powder properties and their reusability are focused upon, as well as process parameters and their influence on part quality. Investigations on density, microstructure, and hardness are shown to illustrate the potential of the SEBM process. Final heat treatments reveal that a further increase in hardness is possible in this alloy.

PBF-EB of Fe-Cr-V Alloy for Wear Applications

“…The cross section of an as built FeCr-10V thin-walled structure is represented by Figure 4a, showing a crack-free and dense sample. Although the wall thickness of 2 mm is much thinner, the microstructure is similar to previous investigations on 10 mm cubic specimens or bigger (Figure 4b) [25]. The microstructure of the cutting crowns revealed a nearly dense and crack free microstructure, too, as given by the cross section in Figure 5a.…”

“…Corresponding flowability of 16 s/50 g and a tapped density of 4.8 g/cm 3 were sufficient for the printing of parts with at least 99.8% of the theoretical density. A detailed powder analysis is reported in a previous publication [25].…”

“…However, most of the materials that have been investigated were non-iron based, as their manufacturing was often combined with high production and material costs, or stainless or maraging steel [ 1 , 2 , 3 , 4 ]. Interest in the use of AM for cost-driven industries, tool steel applications in particular, has been increasing recently, which is reflected in the number of publications in the last years [ 5 , 6 , 7 , 8 , 9 , 10 , 11 , 12 , 13 , 14 , 15 , 16 , 17 , 18 , 19 , 20 , 21 , 22 , 23 , 24 , 25 ].…”

“…Most common publications from Sander, Botero, etc. deal with an FeCrMoVC alloy, Uddeholms Vanadis 4 Extra©, Vibenite© 480 by VBN Components, FeCu-C alloy, and FeCr-10V, respectively [ 7 , 10 , 11 , 23 , 25 , 26 ].…”

Effect of Preheating on the Microstructure, Impact Properties, and Fracture Mechanisms of a Laser Surface‐Hardened High‐Carbon–Chromium Steel

“…Several surface‐strengthening technologies have been used in industrial production, such as surface mechanical rolling treatment, shot peening, surface thermochemical treatment, and laser surface treatment. [ 10–12 ]…”