Sharif Digital Repository

An iron based powder blend has been developed for rapid tooling using a direct laser sintering process. The powder consists of a mixture of different elements including Fe, C, Cu, Mo and Ni. High sintering activities were obtained by tailoring the powder characteristics and optimizing the chemical constituents. The manufacturing of complex-shaped parts is possible at rates of 6.75 cm3/h according to CAD data. The residual porosity is less than 5 vol.%. The bending strength is around 900 MPa and the artifact hardness is 490 HV30. To further improve the service life of tools, the processed parts are sintered again in a vacuum furnace at 1260 °C for 30 min. This enables to manufacture precision... 

The effects of nitriding, nitrocarburizing and shot peening on fatigue behavior of AISI D3 cold work tool steel were investigated. Five batches of fatigue specimens were manufactured according to the ASTM E466-96 standard. All specimens were quenched and tempered to a hardness of 50 HRC. One group of specimens was shot peened with an Almen intensity of 16 A, one group was nitrocarburized, one group was gas nitrided by single stage and another group was also nitrided by double stages. Rotating-bending fatigue tests were carried out. Our results showed that nitriding and nitrocarburizing treatments did not have a beneficial effect on the fatigue resistance of D3 tool steel. Fatigue test... 

This paper focuses on the effects of low temperature (subzero) treatments on microstructure and mechanical properties of H13 hot work tool steel. Cryogenic treatment at -72 °C and deep cryogenic treatment at -196 °C were applied and it was found that by applying the subzero treatments, the retained austenite was transformed to martensite. As the temperature was decreased more retained austenite was transformed to martensite and it also led to smaller and more uniform martensite laths distributed in the microstructure. The deep cryogenic treatment also resulted in precipitation of more uniform and very fine carbide particles. The microstructural modification resulted in a significant... 

In this work, hot tension tests were conducted on as cast and wrought samples of a high carbon high chromium tool steel to study the hot workability under the rolling conditions. The flow curves illustrate the classical shape of dynamic recrystallization (DRX). It is observed that broken carbide nets in the wrought samples result in lower deformation activation energy 398. kJ/mol in comparison to the as cast samples 432. kJ/mol. Necking strains were calculated using the inflection point of the work-hardening (θ) vs. stress curves. Wrought samples show higher hot ductility and lower maximum stress than the as cast ones. It is shown that lower activation energy of deformation and lower stress... 

Stepwise-graded composite layer of M2 tool stel and 17-4PH stainless steel was fabricated by a simple powder layering technique and the isothermal and nonisothermal sintering response of the bilayer were examined. It was shown that the materials exhibit poor compatibility during co-sintering, i.e., the amount of mismatch shrinkage is significant. An improved compatibility was obtained by adding 0.2 wt% B to the stainless steel powder. Formation of relatively dense layer at the bonding zone indicated an enhanced densification rate at the interface. Microstructural studies showed formation of a ferritic interface in M2/17-4PH composite and elongated grains with an intergranular boride phase... 

Electro Discharge Machining (EDM) can be an element of a sustainable manufacturing system. In the present study, the sustainability implications of EDM of special-purpose steels are investigated. The machining quality (minimum surface roughness), productivity (material removal rate) improvement and cost (electrode wear rate) minimization are considered. The influence and correlation of the three most important machining parameters including pulse on time, current and pulse off time have been investigated on sustainable production. Empirical models have been established based on response surface methodology for material removal rate, electrode wear rate and surface roughness. The...