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Processability of a Hot Work Tool Steel Powder Mixture in Laser-Based Powder Bed Fusion

Powder bed fusion of metals using a laser beam system (PBF-LB/M) of highly complex and filigree parts made of tool steels is becoming more important for many industrial applications and scientific investigations. To achieve high density and sufficient chemical homogeneity, pre-alloyed gas-atomized s...

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Autores principales: Hantke, Nick, Großwendt, Felix, Strauch, Anna, Fechte-Heinen, Rainer, Röttger, Arne, Theisen, Werner, Weber, Sebastian, Sehrt, Jan Torsten
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2022
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9000646/
https://www.ncbi.nlm.nih.gov/pubmed/35407990
http://dx.doi.org/10.3390/ma15072658
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author Hantke, Nick
Großwendt, Felix
Strauch, Anna
Fechte-Heinen, Rainer
Röttger, Arne
Theisen, Werner
Weber, Sebastian
Sehrt, Jan Torsten
author_facet Hantke, Nick
Großwendt, Felix
Strauch, Anna
Fechte-Heinen, Rainer
Röttger, Arne
Theisen, Werner
Weber, Sebastian
Sehrt, Jan Torsten
author_sort Hantke, Nick
collection PubMed
description Powder bed fusion of metals using a laser beam system (PBF-LB/M) of highly complex and filigree parts made of tool steels is becoming more important for many industrial applications and scientific investigations. To achieve high density and sufficient chemical homogeneity, pre-alloyed gas-atomized spherical powder feedstock is used. For high-performance materials such as tool steels, the number of commercially available starting powders is limited due to the susceptibility to crack formation in carbon-bearing steels. Furthermore, scientific alloy development in combination with gas-atomization is a cost-intensive process which requires high experimental effort. To overcome these drawbacks, this investigation describes the adaption of a hot work tool steel for crack-free PBF-LB/M-fabrication without any preheating as well as an alternative alloying strategy which implies the individual admixing of low-cost aspherical elemental powders and ferroalloy particles with gas-atomized pure iron powder. It is shown that the PBF-LB/M-fabrication of this powder mixture is technically feasible, even though the partly irregular-shaped powder particles reduce the flowability and the laser reflectance compared to a gas-atomized reference powder. Moreover, some high-melting alloying ingredients of the admixed powder remain unmolten within the microstructure. To analyze the laser energy input in detail, the second part of the investigation focuses on the characterization of the individual laser light reflectance of the admixed alloy, the gas-atomized reference powder and the individual alloying elements and ferroalloys.
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spelling pubmed-90006462022-04-12 Processability of a Hot Work Tool Steel Powder Mixture in Laser-Based Powder Bed Fusion Hantke, Nick Großwendt, Felix Strauch, Anna Fechte-Heinen, Rainer Röttger, Arne Theisen, Werner Weber, Sebastian Sehrt, Jan Torsten Materials (Basel) Article Powder bed fusion of metals using a laser beam system (PBF-LB/M) of highly complex and filigree parts made of tool steels is becoming more important for many industrial applications and scientific investigations. To achieve high density and sufficient chemical homogeneity, pre-alloyed gas-atomized spherical powder feedstock is used. For high-performance materials such as tool steels, the number of commercially available starting powders is limited due to the susceptibility to crack formation in carbon-bearing steels. Furthermore, scientific alloy development in combination with gas-atomization is a cost-intensive process which requires high experimental effort. To overcome these drawbacks, this investigation describes the adaption of a hot work tool steel for crack-free PBF-LB/M-fabrication without any preheating as well as an alternative alloying strategy which implies the individual admixing of low-cost aspherical elemental powders and ferroalloy particles with gas-atomized pure iron powder. It is shown that the PBF-LB/M-fabrication of this powder mixture is technically feasible, even though the partly irregular-shaped powder particles reduce the flowability and the laser reflectance compared to a gas-atomized reference powder. Moreover, some high-melting alloying ingredients of the admixed powder remain unmolten within the microstructure. To analyze the laser energy input in detail, the second part of the investigation focuses on the characterization of the individual laser light reflectance of the admixed alloy, the gas-atomized reference powder and the individual alloying elements and ferroalloys. MDPI 2022-04-04 /pmc/articles/PMC9000646/ /pubmed/35407990 http://dx.doi.org/10.3390/ma15072658 Text en © 2022 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Hantke, Nick
Großwendt, Felix
Strauch, Anna
Fechte-Heinen, Rainer
Röttger, Arne
Theisen, Werner
Weber, Sebastian
Sehrt, Jan Torsten
Processability of a Hot Work Tool Steel Powder Mixture in Laser-Based Powder Bed Fusion
title Processability of a Hot Work Tool Steel Powder Mixture in Laser-Based Powder Bed Fusion
title_full Processability of a Hot Work Tool Steel Powder Mixture in Laser-Based Powder Bed Fusion
title_fullStr Processability of a Hot Work Tool Steel Powder Mixture in Laser-Based Powder Bed Fusion
title_full_unstemmed Processability of a Hot Work Tool Steel Powder Mixture in Laser-Based Powder Bed Fusion
title_short Processability of a Hot Work Tool Steel Powder Mixture in Laser-Based Powder Bed Fusion
title_sort processability of a hot work tool steel powder mixture in laser-based powder bed fusion
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9000646/
https://www.ncbi.nlm.nih.gov/pubmed/35407990
http://dx.doi.org/10.3390/ma15072658
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