Properties of Tool Steels Printed by Directed Energy Deposition Process on S45C Base Metal

We present a fundamental study on the development of trimming dies at room temperature for the hot-stamping process using directed energy deposition. Specimens of G and F materials were fabricated by machining 3D-printed blocks. The hardness of G-layered specimens was slightly higher than that of F-layered specimens, reaching approximately 700 HV at the surface. The G-layered specimens consisted of columnar and equiaxed dendrites, whereas the F-layered specimens mainly consisted of equiaxed dendrites. Spherical pores were observed inside the layered cross section, whereas relatively large irregular-shaped cavities were observed in layered boundaries. The tensile strengths of the G-layered and F-layered specimens were approximately 1800 and 1650 MPa, respectively. During bonding strength tests on an area bonded with S45C base metal, a fracture occurred in one case because of the lack of fusion at the boundary, and the F-layered specimens showed a lower strength than the G-layered ones. During wear tests on a quenched 1.5 GPa-grade aluminized steel plate, the F-layered specimens showed lower wear loss. However, the G-layered specimens showed better wear resistance during wear tests on a 1.5 GPa-grade electrogalvanized steel plate. These findings serve as fundamental data for additive manufacturing processes using tool steels of high-strength materials with high melting points.