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<p>Laser-Based Powder Bed Fusion of Metals (PBF-LB/M) is a widely used additive manufacturing (AM) process. However, its high manufacturing cost, primarily driven by extended build times, remains a significant challenge. In pressure die casting (PDC) applications, core pins made from AISI H13 tool steel are commonly used to create intricate internal features of cast parts. Due to their considerable length and relatively small diameter, ensuring effective heat dissipation is difficult. PBF-LB/M presents an ideal solution for incorporating complex conformal cooling channels, which enhance heat dissipation and improve the overall performance of core pins. However, fabricating the entire core pin using PBF-LB/M can be expensive and time-consuming. A more economical alternative is hybrid AM, where a challenging section of the core pin with conformal cooling channels is AMed onto a conventionally machined AISI H13 tool steel base. This approach significantly reduces build time while retaining the advantages of optimized cooling. In this study, hybrid AM was employed to build the prototype of PDC core pins with conformal cooling channels. The AMed AISI H13 tool steel section was built onto a conventionally machined AISI H13 tool steel base in its soft-annealed condition. The interfacial microstructure was characterized in both the as-built state and after austenitizing and tempering heat treatments. Mechanical properties across the interface were also evaluated. Post-build heat treatment resulted in a homogeneous microstructure across the interface. Tensile testing exhibited a strength of 1723 ± 57&#xa0;MPa, a yield strength of 1504 ± 40&#xa0;MPa, and an elongation of 7.45 ± 1.2%, with ductile failure observed near the interface on the AM side of the hybrid AM sample. The tensile properties were comparable to fully additively manufactured specimens subjected to the same heat treatment. These findings provide valuable insights into the challenges of interfacial microstructure and mechanical behaviour of hybrid AM of AISI H13 tool steel and establish a strong foundation for industrial adoption.</p>

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Evaluating the Interfacial Microstructure and Mechanical Behavior of Hybrid Additive Manufactured AISI H13 Tool Steel

  • 期刊论文

  • 发表日期：

    2025年10月9日

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  • D. M. Santhoshsarang,
  • G. L. Samuel,
  • Ravi Bathe,
  • Gururaj Telasang

摘要

Laser-Based Powder Bed Fusion of Metals (PBF-LB/M) is a widely used additive manufacturing (AM) process. However, its high manufacturing cost, primarily driven by extended build times, remains a significant challenge. In pressure die casting (PDC) applications, core pins made from AISI H13 tool steel are commonly used to create intricate internal features of cast parts. Due to their considerable length and relatively small diameter, ensuring effective heat dissipation is difficult. PBF-LB/M presents an ideal solution for incorporating complex conformal cooling channels, which enhance heat dissipation and improve the overall performance of core pins. However, fabricating the entire core pin using PBF-LB/M can be expensive and time-consuming. A more economical alternative is hybrid AM, where a challenging section of the core pin with conformal cooling channels is AMed onto a conventionally machined AISI H13 tool steel base. This approach significantly reduces build time while retaining the advantages of optimized cooling. In this study, hybrid AM was employed to build the prototype of PDC core pins with conformal cooling channels. The AMed AISI H13 tool steel section was built onto a conventionally machined AISI H13 tool steel base in its soft-annealed condition. The interfacial microstructure was characterized in both the as-built state and after austenitizing and tempering heat treatments. Mechanical properties across the interface were also evaluated. Post-build heat treatment resulted in a homogeneous microstructure across the interface. Tensile testing exhibited a strength of 1723 ± 57 MPa, a yield strength of 1504 ± 40 MPa, and an elongation of 7.45 ± 1.2%, with ductile failure observed near the interface on the AM side of the hybrid AM sample. The tensile properties were comparable to fully additively manufactured specimens subjected to the same heat treatment. These findings provide valuable insights into the challenges of interfacial microstructure and mechanical behaviour of hybrid AM of AISI H13 tool steel and establish a strong foundation for industrial adoption.