Combined production of AISI H13 tool steel using laser-based additive manufacturing and mechanical post-processing to increase service life and durability

The additive manufacturing of H13 tool steel using laser-based powder bed fusion (PBF-LB) enables innovative designs in toolmaking, such as internal cooling channels in die-casting or injection molding tools, which increase their service life. However, due to insufficient dimensional accuracy and high roughness resulting from additive manufacturing, the components require machining or forming as a finishing process. This finishing step has a significant impact on surface and subsurface properties.

By specifically characterizing and adjusting these properties during the manufacturing and finishing process, a new generation of optimized H13 tools is being developed that surpasses the properties of reference tools. Understanding the influences of process parameters and interactions in PBF-LB, milling, and deep rolling on the subsurface properties of H13 steels allows for the targeted adjustment and enhancement of tool durability and service life. Thus, the respective advantages of different manufacturing processes are effectively combined in an integrated process chain.

Objective of the project

The project investigates the influences of process parameters in combined manufacturing (PBF-LB, milling, and deep rolling) and the interactions between these processes on subsurface properties such as hardness, microstructure, residual stress state, and roughness. The knowledge gained is used to optimize the manufacturing process chain. This allows for the precise adjustment of locally defined surface and subsurface properties through both the manufacturing and finishing processes. The goal is to produce high-performance tools made from H13 steels.

Advantages

• Understanding Surface and Subsurface Properties – Along the process chain from PBF-LB, milling, and deep rolling.
• Performance Enhancement of Tools – Longer service life reduces downtime and increases productivity.
• Optimized Combined Manufacturing – Leveraging the advantages of each manufacturing process and integrating them along the process chain.

Procedure

In the DFG project Combined Manufacturing of AISI H13 Tool Steel we collaborate with the Institute of Materials Engineering (IfW) at the University of Kassel to investigate the local surface and subsurface properties of additively manufactured H13 steels. The focus is on the influence of process parameters both in PBF-LB and in the subsequent milling and deep rolling steps on component properties. To achieve this, the components are analyzed metallographically and using X-ray diffraction. By understanding the interactions between the processes, optimized process parameters are developed, enabling the targeted adjustment of H13 steel properties.

Are you also interested in our research topics? Feel free to reach out. 

Contact Philipp Pillkahn by e-mail at pillkahn@ifw.uni.hannover.de or by phone at +49 511 762 5389. We look forward to exchanging ideas!