In the rapidly evolving world of additive manufacturing (AM), a new review published in *Materials & Design* (translated as *Materials & Design*) is shedding light on the intricate processes and challenges of manufacturing and repairing tool steels using two dominant AM techniques: direct energy deposition (DED) and powder bed fusion (PBF). Led by Mohammad Saleh Kenevisi from the Department of Applied Science and Technology at Politecnico di Torino, the research provides a comprehensive overview of how these methods can be optimized for industrial applications, particularly in the energy sector.
Tool steels are critical materials in various industrial applications due to their exceptional wear resistance, toughness, and reliability. However, their production and repair processes have always been fraught with challenges. Kenevisi’s review delves into the distinct mechanisms and material responses characteristic of DED and PBF processes, offering insights into how microstructure, residual stresses, porosity, and carbide chemistry evolve under these techniques.
“Understanding the nuances of each process is crucial for optimizing tool steel production and repair,” Kenevisi explains. “For instance, DED involves larger melt pools and intrinsic tempering, while PBF results in rapid solidification and fine microstructures. Each has its own set of challenges and advantages.”
The review highlights common optimization approaches, preheating strategies, parameter windows, post-processing heat treatments, and robust non-destructive evaluation techniques. These insights are particularly relevant for the energy sector, where tool steels are used in critical components such as turbines, drills, and other high-wear parts. The ability to repair and fabricate these components efficiently can lead to significant cost savings and improved performance.
One of the key challenges addressed in the review is the material compatibility and economic and environmental considerations of AM tooling. Kenevisi notes that while AM offers numerous advantages, such as reduced material waste and the ability to create complex geometries, there are still hurdles to overcome. “Cross-process insights can accelerate industrial adoption,” he says. “By understanding the strengths and limitations of each technique, we can develop more robust and efficient manufacturing processes.”
The review also identifies gaps in current knowledge and discusses future trends, providing a roadmap for further research and development. As the energy sector continues to demand more durable and efficient tools, the insights from this review could shape the future of tool steel manufacturing and repair.
In conclusion, Kenevisi’s work offers a coherent framework that connects AM physics, materials science, and engineering performance for tool steels. By addressing the specific challenges and opportunities presented by DED and PBF processes, this research paves the way for more efficient and sustainable manufacturing practices in the energy sector and beyond.