Additive Manufacturing for Advanced and Functional Tooling of Dies Used in High-Pressure Die Casting Processes

Abstract:

This article aims to review the recent advances in the laser powder bed fusion process (L-PBF) of H13 tool steel for the dies used in the high pressure die casting (HPDC) applications. The effect of processing variables is briefly reviewed for the evolution of microstructure (phase transformations, as-built microstructure and carbides precipitation), mechanical properties, and defects. The second part of the review is focused on conformal cooling applications to HPDC dies, which is critical for die life and productivity. Achieving better microstructure without defects, understanding the role of processing variables in L-PBF and their interdependencies remains the key challenge for the as-built part, while the benefits of preheating and post-heat treatments are evident. Significant benefits are realized in the applications of die inserts favoring lower die surface temperature, reduced cycle time and lubrication, and thermo-mechanical stresses. In addition, L-PBF also plays a key role in die remanufacturing where significant benefits are achieved in terms of materials savings and improved performance compared to traditional repair technologies. Overall, L-PBF offers a transformative pathway for high-performance HPDC dies; however, most investigations are trial-based. Long-term studies are needed for performance assessment and establishing failure mechanisms in production environments.

• Periodical: Materials Science Forum (Volume 1188)
• Pages: 57-73
• Online since: April 2026
• Authors: Sri Harini Rajendran*, Nagasivamuni Balasubramani, Mohamed El Mansori
• Keywords: Additive Manufacturing, High-Pressure Die Casting, Microstructure, Solidification

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