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Procedia CIRP 63 (2017) 58 – 63

The 50th CIRP Conference on Manufacturing Systems

State-of-the-art Laser Additive Manufacturing for Hot-work Tool Steels

Fritz Klockea, Kristian Arntzb, Mahesh Telib,*, Kai Winandsb, Maximilian Wegenerb, Stella Oliarib
a
Laboratory for Machine Tools and Production Engineering, WZL, RWTH Aachen University, Aachen 52074, Germany
b
Fraunhofer Institute for Production Technology IPT, Aachen 52074, Germany
* Corresponding author. Tel.: +49-241-8904-259; fax: +49-241-8904-6259. E-mail address: [email protected]

Abstract

Additive manufacturing (AM) processes are based on the controlled selective deposition of material by which a part is manufactured or
remanufactured (repaired), layer by layer. Research in AM is drastically on the increase in the last several years owing to the benefits that AM
provides over conventional manufacturing i.e. reduction in material usage, time-to-market reduction, improved functionality, increased ability
to customize and near-net shape manufacturing. There has been a number of AM techniques focused on non-metallic materials. In addition,
many industries have already embraced the use of AM for metallic parts using laser as an efficient machining tool, including automotive, die &
mold, aerospace & defense, industrial products, consumer products and health care. However, the research on metallic materials has been
facing a lot of obstacles due to the complexity involved in laser additive manufacturing (LAM) process. This complexity arrives from a
multitude variables involved in the process itself i.e. system design as well as process design variables. As a result, there are nowadays limited
AM technologies commercially available. This can motivate researchers to focus their work in order to ruggedize LAM processes for
commercial large-scale. In this regard, this paper gives the definition and classification of additive manufacturing processes according to
ASTM Standard F2792-12a, followed by a description of principles and future perspectives for fabrication of parts via LAM focused on hot-
work tool steels, and potential future applications of LAM for industries i.e. die & mold, forging and cutting tools and automotive. The present
paper also talks about the barriers to implementation of LAM for hot-work tool steels.
© 2017 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
© 2017 The Authors. Published by Elsevier B.V.
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of The 50th CIRP Conference on Manufacturing Systems.
Peer-review under responsibility of the scientific committee of The 50th CIRP Conference on Manufacturing Systems
Keywords: Laser additive manufacturing; Hot-work tool steels; Productivity

1. Introduction studied for a wider range of metal alloys especially hot-work

tool steels.
Additive manufacturing is a process for making free- Laser additive manufacturing (LAM) is one of the most
formed parts by adding material layer-by-layer in an efficient important AM processes for processing metal alloys. To date,
way. AM uses a tool path, which divides the desired parts into several LAM processes have been developed and
2D layers as compared to conventional process. Subsequently, commercialized to build and/or repair functional metal parts.
these layers are deposited to build up the complete part. This For instance, laser metal deposition (LMD), selective laser
procedure has a number of advantages over conventional sintering (SLS) and selective laser melting (SLM). LAM is
process. For instance, the potential to perform rapid also considered as a cost-effective and near-net shape rapid
prototyping and fabrication of complex products with blind manufacturing process, if hard-to-machine materials have to
machining features like cooling channels. AM has particularly be manufactured [2]. It is used to directly manufacture fully
achieved a lot of success in producing 3D parts made of dense and complex 3D parts like biomedical components or
polymers because of their low melting point and high aero engine components [3, 4, 5]. LMD is implemented to
viscosity, which allow a simple heat input system and nozzle build molding die inserts and light reflectors. The goal of all
designs to be used for precise deposition [1]. However, the these LAM processes has been to minimize raw material
potential of AM in building functional parts has still to be usage, lead time for part production and manufacturing costs

2212-8271 © 2017 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of The 50th CIRP Conference on Manufacturing Systems
doi:10.1016/j.procir.2017.03.073
 Fritz Klocke et al. / Procedia CIRP 63 (2017) 58 – 63 59

while improving the performance and quality of the end landing gears, and gas turbine blade. Therefore, these
product [6]. processes have been used in various industries; for instance,
The motivation for LAM is also driven by advanced space, aircraft, biomedical, automotive and architecture [10].
materials and energy considerations and by industry demands.
The design of highly critical mechanical products often rely
on advanced materials to achieve required performance
characteristics [7]. One material group, which guarantees a
success for several industries, is the group of hot-working
steels. They are widely used in different industries to produce
highly stressed hot-work tool steel products such as molds and
dies for extrusion, forging and die casting tools. Conventional
processes such as casting, vacuum arc remelting (VAR) and
powder metallurgy (PM) are generally used to produce these
steels. However, these processes possess critical drawbacks.
For example, in the case of casting, the process leads to a Fig. 1. Classification of laser additive manufacturing (LAM) [6, 35, 39].
coarse microstructure, which is not desirable to achieve the
best material properties, and although PM greatly controls the 3. Laser additive manufacturing of metallic materials
microstructure-property relation, it contains a number of
critical steps, which make the process expensive [8]. LAM plays a crucial role to reduce the production costs
From a manufacturing standpoint, therefore the challenges especially when machining high-cost, hard-to-cut or hard-to-
for LAM technologies required to transfer materials into final bend metallic materials. It has a number of working principles
products have drastically raised. Each material possesses considering its application. For surface integrity applications,
specific characteristics that make them applicable candidate the substrate can be a wrought product, a forging, a casting or
for a particular application. In this respect, hot-work tool a damaged part. LAM can be achieved by hybrid fusion-based
steels possess strength-at-high-temperature, which makes processes, which use additional energy source such as an
them an appropriate choice for hot-working applications. electron beam, a plasma beam, and/or an electric arc and
Nevertheless, LAM is seldom used to manufacture mechanical metallic powder and/or wire as feedstock [4, 6, 10].
parts made up of these steels. Hence, the present paper Although LAM offers a number of benefits in terms of
addresses the challenges that make LAM less applicable to production lead-time, acquisition cost and performance
manufacture such kind of products. Furthermore, this paper is envisioned, there are significant challenges while developing
outlined to articulate the-state-of-the-art LAM in terms of LAM for metallic material. These challenges are obvious in
manufacturing products of hot-work tool steels. It also talks light of a number of physical phenomena involved in the
about some important LAM processes and their application in process and unavailability of their knowledge. Hence, most of
order to fabricate such products. LAM processes have been used to enhance the surface
integrity of metallic parts i.e. to improve wear, corrosion and
2. Classification of laser additive manufacturing oxidation resistance, and to some extent fatigue resistance [11,
12]. Additionally, LAM can be used to produce functionally
Based on ASTM F2792-12A Standard Terminology for graded materials (FGMs) [13] because it has capability to
Additive Manufacturing Technologies, the following handle various materials at the same time [14]. LAM is
definition has been introduced: Additive Manufacturing (AM) particularly attractive for the production of aerospace parts
is the process of joining materials to make objects from 3D because it can greatly increase fly-to-buy rations [15, 43].
model data, usually layer upon layer, as opposed to subtractive However, applications of the LAM process are limited mostly
manufacturing methodologies [6]. The wording ‘the process to repair a part, and it has been seldom used to build up
of joining materials’ means that AM has an ability to join the complete parts from hot-work tool steels. The reasons for this
same materials or different materials together. This ability is are the difficulties involved while introducing heat into this
used in LAM process to fabricate metallic parts. LAM has material, availability of cost-effective conventional processes,
emerged with the introduction of SLS in 1987. As partially and the industries wherein hot-work tool steel fits are not as
molten powder has been a problem in the beginning of metal critical as aerospace industry.
powder-bed fusion, which is not a desired process feature,
SLS is used purely for plastic processing today. Since then, a 3.1. Process characteristics of LAM for metallic materials
number of LAM processes have been developed to build
and/or repair parts made of hot-work tool steels. LAM for metallic materials are fusion-based processes
According to the ASTM F42 Committee, AM processes built upon traditional welding technologies. Variations in
based on laser and pertained to metal are SLM and wire- and energy input, filler material deposition rates and laser scan
powder-fed direct energy deposition (DED): Direct metal speeds produce a wide variety of alloys, microstructures and
deposition process (DMD) belongs to DED [9]. Fig. 1 gives a geometries due to an undercooling effect [15-17]. Therefore,
classification of LAM processes implemented for hot-work LAM can be implemented to manufacture and investigate
tool steels. Their application focuses on the production or experimental alloys because of its better control over the
repair of functional parts; for example, gear mold insert,
60 Fritz Klocke et al. / Procedia CIRP 63 (2017) 58 – 63

nucleation sites and nucleation growth during solidification

compared to conventional casting [2, 10, 18].
In general, LAM consists of a number of processes
depending upon applications. Fig. 2 shows the working
principle of SLM [6]. The basic powder based system consists
of CAD/CAM model, laser system, scanner, powder
deposition system, building platform and part. The model is
divided into layers with a defined thickness. In the production
unit, each layer is fabricated by selectively melting powder on
the bed with the help of a scanner laser beam. After the short
laser-material interaction, the material swiftly solidifies. In
the subsequent step, the building platform is lowered one-
layer thickness, and a new powder layer is spread by a wiper
and scanned. This cycle is repeated until the complete part is
fabricated. The final part may need surface finishing to
achieve the final surface roughness and tolerances. Excess Fig. 3. Direct material deposition: (a) coaxial powder; (b) lateral wire.
material can be saved and reused, which additionally reduces
manufacturing cost. Every deposition technique (wire or powder) has its pros
and cons, and if combined together then gives new more
advantages (Fig. 4). However, there is limited research done
in order to combine both techniques for hot-work tool steel
applications and push the LAM process a step ahead because
of the complexity involved into the process.

Fig. 2. Principle of selective laser melting (SLM) [6].

Fig. 4. Overview of a combined LAM with powder and wire [21, 22].
3.2. Recent trends in LAM for metallic materials
4. Hot-work tool steels
LAM has witnessed a number of developments in order to
realize its advantages over conventional processes. Many The importance of tool steels extends far beyond what is
researchers have tried to optimize LAM via application of generally perceived as commonplace. Hot-work tool steel is
CAD/CAM [19]. Adaptive toolpath deposition method has massively used to produce highly stressed parts mostly used in
been developed to manufacture and repair turbine compressor hot-working applications. The functionality of hot-work tool
airfoils [20]. In the last couple of years, a number of hybrid steels is defined by their chemical composition, the production
manufacturing systems have been announced with the technology, and the subsequent heat treatment. The correct
combination of LAM and CNC milling or multi-wire heads or choice and application of a steel grade result in considerable
different energy sources such as laser and electron beam. cost savings. In this regard, hot-work tool steel, also called as
These systems are gaining traction in hot-work applications H-type tool steel, influences the production costs, the quality
such as the repair of tools, hard facing and other opportunities of the manufactured parts and the technical possibility for
where it reduces cost of repair applications [21, 39]. shaping materials to final products [11, 23].
Fig. 3 shows the working principle of two deposition The AISI type H steel is available in three subgroups
techniques used for DMD. In Fig. 3(a), powder is fed according to the major alloying element [24]. Group one
coaxially, whereas in Fig 3(b), wire is delivered laterally to consists of Chromium-base AISI hot-work tool steels (types
the molten pool caused by laser energy. In general, powder- H10 to H19), which are suitable for applications such as dies
fed systems are more expensive than wire-fed systems for metal extrusion, die casting and forging. Group two is
because of the critical powder manufacturing process. Tungsten-base AISI hot-work tool steels (types H21 to H26),
which are suitable for applications such as dies for metal
extrusion and forging dies and the last group is Molybdenum-
 Fritz Klocke et al. / Procedia CIRP 63 (2017) 58 – 63 61

base AISI hot-work tool steels (types H42 and H43), mainly
used for forming operations. Accordingly, these three 4.1. LAM for hot-work tool steels
subgroups have different mechanical properties, which make
them suitable for the particular processes (Fig. 5). LAM processes are proving an effective tool to enhance
the performance of hot-work tool steels. The selection of a
specific LAM process is vital for a particular application, and
hence, is based on various criteria such as the group of hot-
work tool steels, the needed energy efficiency, the aimed
deposition rates, and the part design [27]. For a better energy
efficiency, powder-based DMD is more appropriate over
wire-based due to better energy coupling and reduced energy
losses [27]. SLM can be useful for prototype or short run dies
because the process depends on a size of the build chamber,
whereas DMD is a good choice for the manufacture of larger
dies and repair of production dies because of its high
deposition rates and freedom to deposit a plethora of materials
[28]. In general, processes that provide high deposition rates
Fig. 5. Comparison of mechanical properties of AISI type H steels, and their (e.g. wire-based DMD) favour near-net-shape production and
respective processes [8, 24].
subsequent post-process machining like milling and grinding,
whereas processes that use lower build rates like wire- and/or
The chromium hot-work tool steels are the most widely powder-based LAM may offer superior quality [29]. SLM is
studied and commercialized for forging and die-casting more suitable to improve the relationship between
applications because of their resistance to erosion, resistance microstructure and mechanical properties of H13 such as
to thermal fatigue, and reasonable alloy content and costs. hardness, ultimate tensile strength, elongation at fracture, and
H11 is a suitable material for myriad applications because of reduce the material loss [18, 30]. Additionally, SLM can
its outstanding toughness and shock resistance. The tungsten produce denser structure (99%) than SLS because SLM
H-type steels have not become as attractive as chromium H- completely melts the material, which later solidifies without
type steels because of their low resistance to thermal shock forming spherical voids (the left-hand side of Fig. 6), whereas
and high probability of breakage during quenching. The SLS produced parts can exhibit a number of voids (the right-
gradual use of molybdenum H-type tool (H42) has declined hand side of Fig. 6). Therefore, SLM can produce the high
due to high cost [24]. There is a constant progress in strength parts compared to SLS. This could be another reason
developing new hot-work tool steels with enhanced for abandoning SLS for metallic parts.
properties, which make them more suitable candidate for
existing as well as new applications. High strength ferrite-
martensite laminated steel has been developed with improved
Charpy impact toughness [25]. The development of new hot-
work tool steel called as Thermodur E 40 K Superclean
(electro-slag remelted) is reported recently in the scientific
literature [26], and is being commercialized. It has chemical
composition (in weight-%) as 0.35% carbon, 0.3% silicon,
0.3% manganese, 5.0% chromium, 1.75% molybdenum and
0.8% vanadium. It offers the better combination of high
temperature stability and toughness for highly stressed tools
compared to other proven hot-work tool steels like H11 and Fig. 6. Structure by SLM (dense on left) and SLS (porous on right) [35].
H13.
However, during application, hot-working tools are heavily Moreover, a LAM process has be chosen based on its
loaded, and the materials have to withstand very high thermo- application. First application is for surface properties
mechanical loads, which limit their lifetime. Hence, the steel enhancement. Being referred as LMD in the context of AM,
material should possess the following general characteristics: laser cladding of NiTi on H13 tool steel surface is found to be
Resistance to deformation at high temperature, mechanical effective in order to improve superficial properties, especially
and thermal shock resistance, high-temperature wear, heat hardness and wear resistance [31]. If alloying elements, for
checking and good toughness [23, 24, 26]. These example, niobium, vanadium and tungsten, are introduced
characteristics hugely depend upon steel making process and into the liquid metal pool created by laser, a noticeable
further production route used. Therefore, it remains improvement of mechanical properties of the steels is seen as
motivation for researchers to develop new LAM processes to compared to those produced by conventional process such as
improve the productivity of tooling processes, to facilitate toughness and thermal fatigue resistance [32, 33]. Thick
new innovative tooling processes, to add value to other metallic coatings created on the steel surface by laser cladding
components by repairing features, adding new features to an have improved wear resistance, which resulted in high
existing component and/or coating a component and increase lifetime of dies of H13 tool steel [33].
the lifetime of the component/tool.
62 Fritz Klocke et al. / Procedia CIRP 63 (2017) 58 – 63

Second application is for near-net shape fabrication based hardening, which allows the automotive industry to produce
on DMD process. It is an evolving CAD/CAM technology high-strength parts.
that utilizes a laser beam to melt deposited wire and/or
powder to form a functional component layer-by-layer. This 6. Barriers to implementation of LAM
laser based process does not need any molds or dies and
hence provides the flexibility to quickly change the In order to achieve a wider spectrum of applications for
component design. This feature quietly suits to the industries’ LAM of hot-work tool steels, R&D efforts will need to
demand i.e. time to market. DMD is more effective compared overcome the challenges. The need for using a broader range
to SLM in terms of development of FGMs like Inconel-steel of materials, to set-up production of complex and large parts
FGM [14]. Fig. 3(a) shows the working principle of powder- and products, the need of skilled workforce in LAM, proper
based DMD, which has been used to build a freeform by assessment for cost- effectiveness, need to improve the
using laser to consolidate H13 and CPM 9V tool steel (CPM: precision and reliability of LAM process to increase
crucible particle metallurgy) [34]. However, powder-based throughput while maintaining consistent quality, LAM needs
DMD process has maximal defects compared to wire because to be validated, demonstrated and standardized [4, 6, 9, 33].
the technology for wire is transferrable from mature welding As a known fact, a process does not come smoothly but with
consumable supply chain. Although the parts built using these challenges. LAM is not exceptional to the fact and comes
LAM processes are metallurgically sound and free of cracks, with both opportunities and challenges (Fig. 7).
concerns have been raised about surface finish and
dimensional accuracy. However, it can be reduced in the post-
process [36].

5. Impact of LAM processes on industries

Hot-work tool steels are being crucial for die and mold
making, forging as well as for cutting tool industry. These
industries facilitate the success of aeronautics, automotive,
electronics, household equipment goods and micro-devices. It Fig. 7. LAM opportunities and challenges [6, 37, 38, 43].
is believed that LAM will grow into a sizeable market as
SLM and DMD for H-type steels are further researched and 7. Conclusion and outlook
refined [6, 9]. Currently, these technologies are extensively
used to remanufacture and repair dies and molds made of hot- There is a broad spectrum of available LAM technologies
work tool steels, which resulted in the expected reduction of for the machining of hot-work tool steel materials. Since the
replacement cost and the promise of better mechanical and hot-work tool steel influences the production cost and the
wear resistance [41]. Hot-work steel tools are also used for quality of produced parts, there could be an exciting
hot stamping tools, which are further implemented to possibility for LAM to fabricate H-type steel tool parts that
manufacture high strength automotive body parts. Therefore, could not be fabricated easily using conventional practices.
another application for SLM and DMD lies in producing hot Examples include die & mold, forging and cutting tools that
stamping tools with improved cooling efficiency [40]. These can be built with the exact geometry output using CAD/CAM
applications also assure better or equal to warranty part or advanced forming tools with specific cooling channel.
quality. Moreover, the opportunity created by SLM and DMD However, there are a limited number of technologies
presents the possibility for large reductions in energy commercially available and there is a great deal of work to be
consumption and environmental emissions [42]. done on ruggedizing the processes for commercial scale
LAM has huge potential to contribute in different ways manufacturing.
within the tooling industry. On the one side, it can be applied There is a need to understand the material microstructure
for the production of tooling, and on the other side, it can resulting from LAM process, the comprehensive material
function as tooling substitute. These potentials provide property database and a testing methodology. A lot of studies
numerous benefits as compared to conventional have to be done in order to assess the effect of processing
manufacturing technologies. It also simplifies manufacturing parameters on fatigue strength, fracture toughness and creep.
processes; for instance, regarding the realization of cooling A real time test will be necessary to fully understand the
channels within the tooling [37]. LAM is already becoming a performance of LAM parts in service like conditions. The
useful production tool within the industries, and it is reflected newly formed ASTM F42 committee is working to write
by the positive impact on the market development [6, 37]. standards that address a wide array of these needs.
H-type tool steels are used in automotive industry in order To date, there has been a relatively large work focused on
to produce parts such as prototypes, customized tools and Ti-6Al-4V, but not much on hot-work tool steels. These steels
investment castings. In this respect, SLM and DMD can be could be manufactured using LAM processes that heretofore
strategic technologies for R&D of these parts because of its have not been extensively investigated. Directed Digital
potential to shorten the development cycle and reduce Manufacturing is upcoming technology, which can open the
production costs. From future point of view, LAM could be door to many exciting and novel applications for hot-work tool
utilized to fabricate tools of hot-work tool steels used in press steels. LAM is foreseen to become more important in the
 Fritz Klocke et al. / Procedia CIRP 63 (2017) 58 – 63 63

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