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Comparative Study of Different Additive Manufacturing Methods for H13 Tool Steel
Paweł Widomski1, Marcin Kaszuba1, Daniel Dobras1
1Department of Metal Forming, Welding and Metrology, Faculty of Mechanical Engineering, Wroclaw University of Science and Technology, 50-371 Wrocław, Poland.
Materials (Basel, Switzerland)
|December 11, 2025
Summary
Additive manufacturing (AM) of H13 tool steel using Laser Powder Bed Fusion (LPBF) and Directed Energy Deposition (DED) yields high-density parts suitable for functional tooling. Binder Jetting (BJ) also shows promise after heat treatment, unlike Fused Deposition Modeling and Sintering (FDMS).
Area of Science:
- Materials Science
- Manufacturing Engineering
- Metallurgy
Background:
- Additive manufacturing (AM) enables complex tool fabrication with H13 hot-work tool steel, reducing waste and production time.
- AM offers potential for conformal cooling in tools, enhancing performance and lifespan.
Purpose of the Study:
- To compare five metal AM technologies for H13 tool steel: FDMS, BJ, LPBF, and DED.
- To evaluate the as-printed microstructure, porosity, and heat treatment response of AM H13 tool steel.
- To determine the suitability of different AM processes for functional tooling applications.
Main Methods:
- Comparison of five AM technologies: Fused Deposition Modeling and Sintering (FDMS), Binder Jetting (BJ), Laser Powder Bed Fusion (LPBF), and Directed Energy Deposition (DED).
- Microstructural analysis, porosity measurement, and evaluation of post-processing heat treatment (quenching and tempering).
- Hardness testing (HV0.5) and microstructural characterization of as-printed and heat-treated samples.
Main Results:
- FDMS and BJ showed high porosity (6-9%), while LPBF and DED achieved near-full densification (<0.1%).
- BJ samples achieved satisfactory hardness after tempering and quenching, with secondary carbide precipitation.
- LPBF and DED samples exhibited stable martensitic structures with hardness around 600 HV0.5 after heat treatment.
- Microstructure and carbide distribution were dependent on the thermal history of each AM process.
Conclusions:
- LPBF and DED are suitable for functional H13 tool steel applications due to superior density and mechanical integrity.
- FDMS and BJ are cost-effective for low-density prototypes but less ideal for demanding tooling.
- Heat treatment significantly impacts the microstructure and hardness of AM H13 tool steel, with process-specific thermal histories playing a crucial role.
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