Effect of heat treatment and defects on the tensile behavior of a hot work tool steel manufactured by laser powder bed fusion

Microstructure and tensile properties of a hot work tool steel manufactured via laser powder bed fusion (LPBF) were investigated. Specimens were built under two different orientations and subjected to two quenching and tempering heat treatments, featuring different austenitizing and tempering temperatures and the eventual presence of a sub-zero step. Microstructural analyses revealed a homogeneous tempered martensite structure after both heat treatments, with the only distinction of a higher alloying segregation at a sub micrometric scale length in samples subjected to the highest tempering temperatures. Hardness and tensile tests indicated a negligible effect of building orientation on mechanical properties, but a significant influence of heat treatment parameters. The treatment featuring the lower tempering temperatures and the sub-zero step resulted in higher hardness, tensile strength, and elongation, attributed to a lower martensite tempering and alloying segregation. Tensile fracture occurred via crack initiation and unstable propagation from large LPBF defects in all the investigated conditions.