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<p>Additive manufacturing (AM) of H13 tool steel using the powder bed fusion (PBF) method is often limited by issues such as porosity (including lack of fusion, gas, and keyhole porosity), balling formation, and elemental segregation. These factors significantly impact the mechanical properties of the final product. This research investigates how volumetric energy density (VED) influences these issues and their subsequent effects on mechanical properties. VED affects the mechanical properties in multifaceted ways. An optimized VED prevents a lack of fusion and minimizes gas and keyhole porosities, especially near edges, ultimately reducing the material’s susceptibility to fracture under tensile load. Additionally, VED influences elemental segregation within a single laser track during the process; lower VED leads to less elemental segregation. This reduced segregation minimizes oxide formation, which are crack initiation sites after heat treatment, thereby enhancing mechanical strength. The study also identifies that an optimal VED minimizes balling formation, further reducing elemental segregation and improving mechanical properties. A VED range of 57–59&#xa0;J/mm<sup>3</sup> is found to be optimal for preventing a lack of fusion, minimizing segregation, and reducing near-surface defects. Furthermore, a relationship is established between these defects, the microhardness profile, and the mechanical properties, suggesting that microhardness can serve as a predictive tool for the mechanical properties of PBF-ed metal.</p>

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Processing parameters optimization for enhanced mechanical strength in PBF-ed H13 tool steel: minimizing manufacturing defects including microstructural inhomogeneity, sub-surface porosities, and oxide formation

  • 期刊论文

  • 发表日期：

    2025年1月11日

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  • Narges Omidi,
  • Manel Houria,
  • Mohamed Meher Monjez,
  • Mohammad Jahazi,
  • Noureddine Barka,
  • Abderrazak El Ouafi

摘要

Additive manufacturing (AM) of H13 tool steel using the powder bed fusion (PBF) method is often limited by issues such as porosity (including lack of fusion, gas, and keyhole porosity), balling formation, and elemental segregation. These factors significantly impact the mechanical properties of the final product. This research investigates how volumetric energy density (VED) influences these issues and their subsequent effects on mechanical properties. VED affects the mechanical properties in multifaceted ways. An optimized VED prevents a lack of fusion and minimizes gas and keyhole porosities, especially near edges, ultimately reducing the material’s susceptibility to fracture under tensile load. Additionally, VED influences elemental segregation within a single laser track during the process; lower VED leads to less elemental segregation. This reduced segregation minimizes oxide formation, which are crack initiation sites after heat treatment, thereby enhancing mechanical strength. The study also identifies that an optimal VED minimizes balling formation, further reducing elemental segregation and improving mechanical properties. A VED range of 57–59 J/mm3 is found to be optimal for preventing a lack of fusion, minimizing segregation, and reducing near-surface defects. Furthermore, a relationship is established between these defects, the microhardness profile, and the mechanical properties, suggesting that microhardness can serve as a predictive tool for the mechanical properties of PBF-ed metal.