Dual-Laser PBF-LB Processing of a High-Performance Maraging Tool Steel FeNiCoMoVTiAl

Area of Science:

• Materials Science
• Additive Manufacturing
• Metallurgy

Background:

• High-performance tool steels are crucial for advanced manufacturing processes like die, forming, and cutting.
• Laser powder bed fusion (PBF-LB) is a key additive manufacturing technology for creating complex tool components.
• Previous work qualified a new maraging tool steel (FeNiCoMoVTiAl) for PBF-LB, achieving high material density.

Purpose of the Study:

• To investigate the impact of dual-laser processing strategies on the microstructure and mechanical properties of a maraging tool steel.
• To explore optimization potential beyond standard single-laser PBF-LB techniques.
• To understand how in-situ modifications of thermal gradients affect material properties.

Main Methods:

• Utilized a dual-laser PBF-LB system with synchronized lasers on the same scanning track.
• Modified build data and varied laser-based post-heating parameters.
• Analyzed changes in material structure and measured microhardness.

Main Results:

• Dual-laser processing enabled in-situ modification of thermal gradients compared to single-laser strategies.
• Achieved a microhardness increase of up to 15%, from 411 HV to 471 HV.
• Demonstrated property changes directly linked to the modified thermal gradients.

Conclusions:

• Dual-laser processing offers significant potential for enhancing the mechanical properties of tool steels produced via PBF-LB.
• This approach allows for tailored microstructural modifications and property optimization.
• Results pave the way for producing functionally graded high-performance components using synchronized multi-laser PBF-LB systems.