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<p>Additive manufacturing (AM), and in particular laser-based powder bed fusion of metals (PBF-LB/M), is increasingly being used in tooling applications. Commonly used steels such as 1.2709 and 1.2344 are commercially available, while other grades such as 1.2379 cannot be processed easily with PBF-LB/M due to limited powder availability and poor weldability. In addition, tool steels are highly alloyed and often contain conflict-related raw materials that critically affect long-term material availability. To address this challenge, this study presents a comparative material selection method based on a key performance indicator that evaluates the alloy compositions in terms of their supply chain resilience and suitability for tooling applications. In this context, resilience is primarily defined by combining the chemical composition with the achievable hardness. Based on this, low-alloy steel 1.7228 was identified as a promising replacement for high-alloy cold work steels. A powder made from 1.7228 was produced specifically, suitable process parameters were developed using correlation analysis and mechanical properties in the as-built state were determined and compared with other available tooling steels for PBF-LB/M (1.2709, 1.4125). The results show that 1.7228 has a higher average impact energy of 45 J than 1.4125 with 4 J. In addition, 1.7228 achieves a higher tensile strength (1,547 MPa) than other materials and higher hardness values (477 HV50) than 1.2709 (340&#xa0;HV50). These experimental results show that 1.7228 enables material substitution for application-specific scenarios, maintaining or exceeding mechanical performance, which supports the sustainable use of scarce raw materials and the need for heat treatments.</p>

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A novel approach to resilience in cold-work applications: experimental comparison of the as-built mechanical properties of high-alloy 1.2709, high-alloy 1.4125 and low-alloy 1.7228 produced using PFB-LB/M

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年6月24日

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  • Johannes Ernstberger,
  • Maximilian Fischer,
  • Christian Seidel

摘要

Additive manufacturing (AM), and in particular laser-based powder bed fusion of metals (PBF-LB/M), is increasingly being used in tooling applications. Commonly used steels such as 1.2709 and 1.2344 are commercially available, while other grades such as 1.2379 cannot be processed easily with PBF-LB/M due to limited powder availability and poor weldability. In addition, tool steels are highly alloyed and often contain conflict-related raw materials that critically affect long-term material availability. To address this challenge, this study presents a comparative material selection method based on a key performance indicator that evaluates the alloy compositions in terms of their supply chain resilience and suitability for tooling applications. In this context, resilience is primarily defined by combining the chemical composition with the achievable hardness. Based on this, low-alloy steel 1.7228 was identified as a promising replacement for high-alloy cold work steels. A powder made from 1.7228 was produced specifically, suitable process parameters were developed using correlation analysis and mechanical properties in the as-built state were determined and compared with other available tooling steels for PBF-LB/M (1.2709, 1.4125). The results show that 1.7228 has a higher average impact energy of 45 J than 1.4125 with 4 J. In addition, 1.7228 achieves a higher tensile strength (1,547 MPa) than other materials and higher hardness values (477 HV50) than 1.2709 (340 HV50). These experimental results show that 1.7228 enables material substitution for application-specific scenarios, maintaining or exceeding mechanical performance, which supports the sustainable use of scarce raw materials and the need for heat treatments.