Microstructural Characterization Of H13 Tool Steel Powder Feedstock For Optimized Process Parameters To Enhance Part Properties In Directed Energy Deposition Additive Manufacturing

Additive manufacturing relies on extensive parameter optimization before deposition to predict the behavior and properties of the final parts. This research will focus on powder H13 tool steel samples produced using directed energy deposition (DED). The objective of the study is to provide a practical foundation for repairing and refurbishing worn or damaged components to extend their service life. The principal methodology involves characterizing the powder and understanding its individual components, including powder size distribution, morphology, flowability, and chemistry. The powder will be used to produce single-track, patch-test, single-bead-wall, and thin-wall samples at separate powder flows and powdering rates. The samples will be mechanically tested, and their microstructure will be evaluated to understand their behavior under varying conditions better. Their yield strength, ultimate tensile strength, and Young's modulus were compared with H13 tool steel rod data to identify shortcomings in the parameters to which the powder was exposed. The microstructural analysis revealed that the powder had a uniform chemistry and was consistent with the information provided by the manufacturer. The powder was analyzed using an optical powder analyzer (Camsizer X2) to determine its size distribution, which indicated that the powder was larger. The powder was repeatedly tested to visualize the particles and elucidate the microstructure. This influences the parameters used to produce powder-based parts. Continuing to understand this material allows innovators to unlock its full mechanical properties. The study concluded that the powder has high mechanical properties even in the as-built condition. H13 tool steel components have shown, across various trials, that high laser power produces significant microstructural defects that ultimately affect the consistency of mechanical properties. This insight contributes to a deeper understanding of h13 tool steel parts produced by directed energy deposition and focuses on the role of each parameter.