This review investigates the state of additive manufacturing (AM) of tool steels with a clear, process-aware scope that centers on two dominant AM routes, direct energy deposition (DED) and powder bed fusion (PBF), and their respective roles in fabrication and repair. First, different categories of tool steels and their common damage mechanisms are introduced. The distinct process mechanisms, material responses, and performance metrics characteristic of each technique is outlined, and then how microstructure, residual stresses, porosity, and carbide chemistry emerge under DED and PBF processes for different type of alloys are explained. By contrasting process-specific challenges, such as larger melt pools and intrinsic tempering in DED versus rapid solidification and fine microstructures in PBF, with end-use requirements, e.g. wear resistance, toughness, and reliability in tooling, we reveal common optimization approaches, preheating strategies, parameter windows, post-processing heat treatments, and robust non-destructive evaluation are delineated in this work. The review also assesses the material compatibility, challenges, and economic and environmental considerations of AM tooling, and highlights gaps where cross-process insights can accelerate industrial adoption and discussed future trends. The aim is to provide a coherent, process-aware framework that connects AM physics, materials science, and engineering performance for tool steels.

Tool steels and their additive manufacturing for fabrication and repair via PBF and DED processes: techniques, challenges, and applications / Kenevisi, Mohammad Saleh; Gobber, Federico Simone; Fino, Paolo; Lombardi, Mariangela; Bondioli, Federica; Biamino, Sara; Ugues, Daniele. - In: MATERIALS & DESIGN. - ISSN 0264-1275. - 258:(2025). [10.1016/j.matdes.2025.114639]

Tool steels and their additive manufacturing for fabrication and repair via PBF and DED processes: techniques, challenges, and applications

Kenevisi, Mohammad Saleh;Gobber, Federico Simone;Fino, Paolo;Lombardi, Mariangela;Bondioli, Federica;Biamino, Sara;Ugues, Daniele
2025

Abstract

This review investigates the state of additive manufacturing (AM) of tool steels with a clear, process-aware scope that centers on two dominant AM routes, direct energy deposition (DED) and powder bed fusion (PBF), and their respective roles in fabrication and repair. First, different categories of tool steels and their common damage mechanisms are introduced. The distinct process mechanisms, material responses, and performance metrics characteristic of each technique is outlined, and then how microstructure, residual stresses, porosity, and carbide chemistry emerge under DED and PBF processes for different type of alloys are explained. By contrasting process-specific challenges, such as larger melt pools and intrinsic tempering in DED versus rapid solidification and fine microstructures in PBF, with end-use requirements, e.g. wear resistance, toughness, and reliability in tooling, we reveal common optimization approaches, preheating strategies, parameter windows, post-processing heat treatments, and robust non-destructive evaluation are delineated in this work. The review also assesses the material compatibility, challenges, and economic and environmental considerations of AM tooling, and highlights gaps where cross-process insights can accelerate industrial adoption and discussed future trends. The aim is to provide a coherent, process-aware framework that connects AM physics, materials science, and engineering performance for tool steels.
File in questo prodotto:
File Dimensione Formato  
Final version_reduced_size.pdf

accesso aperto

Tipologia: 2a Post-print versione editoriale / Version of Record
Licenza: Creative commons
Dimensione 1.63 MB
Formato Adobe PDF
1.63 MB Adobe PDF Visualizza/Apri
Pubblicazioni consigliate

I documenti in IRIS sono protetti da copyright e tutti i diritti sono riservati, salvo diversa indicazione.

Utilizza questo identificativo per citare o creare un link a questo documento: https://hdl.handle.net/11583/3002754