Combined wire- and powder-based laser metal deposition for tool life enhancement in abrasive environments

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Ali Rajaei © Copyright: IWM


Ali Rajaei

Manager Research field Heat Treatment


+49 241 80 99544




The wear resistance of hot forming tools is the limiting factor for their life time. Abrasive wear is the most common reason for tool failure. The wear along the tool is not uniformly distributed and highly stressed regions leads to a failure of the complete tool. With an opportunity for local repair or a local individual wear coating the tool life could be enhanced significantly.


Within the project graded wear resistant coatings made from hot working steels and titanium carbide are investigated for their use in hot forming tools. The production is done by the new production technology LMD-w+p, which combines laser metal deposition of a wire with the addition of the hard titanium carbide powder. By control of the powder flow the graded layers are generated. Within the project the materials and process parameters are investigated to optimize the mechanical properties for the stated application. Additionally, a CAM strategy is developed to apply the new process to other machinery and more complex part geometries.

Project contents

  • Material Development with support of Calphad method
  • Understanding of the residual stresses within the coating in dependence of the hard phase content (residual stress measurements and numerical simulation)
  • Optimization of the materials by correlation of process parameters and microstructure
  • Mechanical and Thermo-physical characterization of the coatings
  • CAD/CAM-Development
  • Production and testing of demonstration tools

Project Partners

  • Fraunhofer-Institut für Produktionstechnologie IPT
  • Forschungsvereinigung Programmiersprachen für Fertigungseinrichtungen e.V.
  • Companies on the project committee: 3win Maschinenbau GmbH, ACAM Aachen Center for Additive Manufacturing GmbH, CAMaix GmbH, Deutsche Edelstahlwerke Specialty Steel GmbH, ESI Software Germany GmbH, EXAPT Systemtechnik GmbH, Hermann Fliess & Co GmbH, Hirschvogel Umformtechnik GmbH, Königs-IT, ModuleWorks GmbH, Schumag AG, SMS Group
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IGF-Grant number: 21667N