Hybrid Selective Laser Melting, Direct Energy Deposition process strength-based optimization for Hot-Forming Tool

Metal additive manufacturing (AM) and especially direct energy deposition (DED) through laser metal deposition (LMD), enables economically viable, high performance, optimized components, such as, nickel alloy complex geometry turbine blades. Also, when combined with complementing technologies such as selective laser melting (SLM) and various post processing techniques, advanced products in less technological intensive industries may also be developed with added value features. One example of such is tooling for high temperature forming, with integrated optimized cooling and simultaneous high wear resistance surfaces. However, these AM processes result in complex microstructures which affect their mechanical performance, especially given the demanding loading scenarios which the applications they are designed for require. This study makes use of Design of Experiments (DoE) approach to study the effect of LMD process parameters on hybrid SLM-LMD tool steel components strength, towards the application of this hybrid manufacturing approach in hot forming tooling.