Rapid manufacturing of hybrid tools made of tool steel and tungsten carbide-cobalt

The Rapid Manufacturing process 'Laser Sintering' is a powder metallurgical process. The process principle is based on a local consolidation, e.g. melting or sintering, of powdered materials as a result of the absorption of laser radiation. For this purpose a powder layer is applied onto a build up plate through a wiping system. A laser beam consolidates defined areas, being directed over the material by a scanner device. Through the cyclic repetition of material application, consolidation and the lowering of the build up plate, a three dimensional geometry develops. The authors present investigations on the manufacture of hybrid tools made of tool steel and tungsten carbide-cobalt. The aim of the research activities is to manufacture a base body of a tool using a tool steel powder. Tool's components with internal geometries, cavities or undercuts can be manufactured with a high build up rate by a Rapid Manufacturing process using a tool steel powder. After changing the powder the process can be continued to manufacture defined tool's geometrical elements using a WC-Co powder. The resulting hybrid tools feature a high complexity level and a high resistance against wear in defined areas.