Combined production of AISI H13 tool steel using laser-based additive manufacturing and mechanical finishing to increase performance and durability

• Applicants: Dr.-Ing. Benjamin Bergmann, since 11/2024; Professor Dr.-Ing. Thomas Niendorf
• Subject Area: Mechanical Properties of Metallic Materials and their Microstructural Origins ; Materials in Sintering Processes and Generative Manufacturing Processes
• Term: since 2023
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 528603925

In industrial applications, hot work tool steels are used for high wear resistance and good thermal shock resistance. The challenge to constantly increase efficiency pushes alloys in die-casting tools to their limits. This fact raises the need for innovative manufacturing processes. Additive manufacturing, due to its unprecedented design potentials, allows the component properties to be adapted to local requirements via tailoring local microstructures. In die-casting tools, high demands are set regarding surface quality. These only can be achieved by additive manufacturing in combination with subsequent milling, which again influences the surface properties. Within the scope of the project applied for, production factors of the combined production chain of additive manufacturing and milling and deep rolling post-treatment are to be elaborated using statistical experimental design. Here, it is intended to establish different material properties. Differently processed conditions will be characterized in detail in terms of their microstructural and mechanical properties and their interrelationships, assessed using response surface methodology. In the further course of the project, specimens with specifically tailored zones of different hardness and tensile strength will be established on top of each other and the transition zone in particular will be extensively investigated. Finally, the specimens will be subjected to thermal fatigue to test the durability of the combined fabricated specimens with locally different properties and finally to assess the overall factor-target correlation using the response surface methodology to eventually allow for transfer of results to other alloy systems.

• DFG Programme: Research Grants
• Ehemaliger Antragsteller: Professor Dr. Bernd Breidenstein, until 10/2024