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Application of direct laser melting to restore damaged steel dies

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Abstract

Direct laser melting (DLM) technology can be applied to restore damaged steel dies. To understand the effects of DLM process parameters such as the laser power and scan rate, a series of experiments was conducted to determine the optimal operating parameters. To investigate the laser melting characteristics, the depth/height ratio, depth/width ratio and micro-hardness as a function of the laser energy density were analyzed. Fe-Cr and Fe-Ni layers were deposited on a steel die with 11.38 J/mm2 of energy input. The wear-resistance and the friction coefficient of the deposited layer were investigated by a pin-on-disk test. The penetration depth decreased as the scan rate increased as a consequence of the shorter interaction time. The depth/height ratio of the deposited layer decreased with an increase in the scan rate. The depth/width ratio increased as laser power increased and the scan rate decreased. The deposition shape of the Fe-Ni powder was relatively shallow and wide compared with that of the Fe-Cr powder. The scan rate had a substantial effect upon the deposition height, with the Fe-Cr powder melting more than the Fe-Ni powder. The micro-hardness of the layer melted from the powders is higher than that of the substrate, and the hardness of the laser-surface-melted layer without any metal powder is higher compared to that of the metal-powder-melted layer. The direct laser melting process with Fe-Ni powder represents a superior method when restoring a steel die when the bead shape and hardness of the restored surface are important outcome considerations.

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Authors and Affiliations

  1. School of Mechanical Engineering/Engineering Research Center for Net Shape and Die Manufacturing, Pusan National University, Busan, 609-735, Korea

    Jeong Hwan Jang, Byeong Don Joo, Sung Min Mun, Min Young Sung & Young Hoon Moon

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  1. Jeong Hwan Jang
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  2. Byeong Don Joo
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  3. Sung Min Mun
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  4. Min Young Sung
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  5. Young Hoon Moon
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Correspondence to Young Hoon Moon.

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Jang, J.H., Joo, B.D., Mun, S.M. et al. Application of direct laser melting to restore damaged steel dies. Met. Mater. Int. 17, 167–174 (2011). https://doi.org/10.1007/s12540-011-0223-z

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  • DOI: https://doi.org/10.1007/s12540-011-0223-z

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