Application of Powder-Bed Fusion of Metals Using a Laser for Manufacturing of M300 Maraging Steel Tools Intended for Sheet Metal Bending

Abstract

This paper presents the results of a pilot application of Powder-Bed Fusion of Metals Using a Laser (PBF-LB/M) for the fabrication of M300 (1.2709) maraging steel sheet metal bending tools. S235 steel was used as a substrate for the fabrication of bending punches. The main goal of the research was to determine the usability of such tools without heat treatment, which would contribute to the increase in the cost of tool production. Industrial tests of tools were conducted during the forming of Inconel 625 and AW-6061 T0 aluminium alloy sheets. The punches were subjected to tests of surface roughness, hardness, microstructure, porosity, and geometric quality in order to verify the quality and accuracy of tools made by the PBF-LB/M technique before and after experimental investigations in industrial conditions in a selected manufacturing company. It was found that tools with an M300 steel working layer after the PBF-LB/M process without heat treatment show suitability for bending sheet metal in a certain range of force parameters, ensuring obtaining elements after bending from Inconel 625 and AW-6061 T0 aluminium alloy sheets of the required geometric quality.