Tribological Performance of Direct Metal Laser Sintered 20MnCr5 Tool Steel Countersamples Designed for Sheet Metal Forming Applications
This article presents the results of the tribological performance of 20MnCr5 (1.7147) tool steel countersamples produced by Direct Metal Laser Sintering (DMLS), as a potential material for inserts or working layers of sheet metal forming tools. Tribological tests were performed using a roller-block...
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MDPI AG
2025-08-01
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| author | Krzysztof Żaba Marcin Madej Beata Leszczyńska-Madej Tomasz Trzepieciński Ryszard Sitek |
| author_facet | Krzysztof Żaba Marcin Madej Beata Leszczyńska-Madej Tomasz Trzepieciński Ryszard Sitek |
| author_sort | Krzysztof Żaba |
| collection | DOAJ |
| description | This article presents the results of the tribological performance of 20MnCr5 (1.7147) tool steel countersamples produced by Direct Metal Laser Sintering (DMLS), as a potential material for inserts or working layers of sheet metal forming tools. Tribological tests were performed using a roller-block tribotester. The samples were sheet metals made of materials with significantly different properties: Inconel 625, titanium-stabilised stainless steel 321, EN AW-6061 T0 aluminium alloy, and pure copper. The samples and countersamples were analysed in terms of their wear resistance, coefficient of friction (COF), changes in friction force during testing, and surface morphology after tribological contact under dry friction conditions. The tests were performed on DMLSed countersamples in the as-received state. The largest gain of countersample mass was observed for the 20MnCr5/EN AW-6061 T0 friction pair. The sample mass loss in this combination was also the largest, amounting to 19.96% of the initial mass. On the other hand, in the 20MnCr5/Inconel 625 friction pair, no significant changes in the mass of materials were recorded. For the Inconel 625 sample, a mass loss of 0.04% was observed. The basic wear mechanism of the samples was identified as abrasive wear. The highest friction forces were observed in the 20MnCr5/Cu friction pair (COF = 0.913) and 20MnCr5/EN AW-6061 T0 friction pair (COF = 1.234). The other two samples (Inconel 625, 321 steel) showed a very stable value of the friction force during the roller-block test resulting in a COF between 0.194 and 0.213. Based on the changes in friction force, COFs, and mass changes in friction pair components during wear tests, it can be concluded that potential tools in the form of inserts or working layers manufactured using 3D printing technology, the DMLS method, without additional surface treatment can be successfully used for forming sheets of 321 steel and Inconel 625. |
| format | Article |
| id | doaj-art-f64e96e4f34c4d87ad11a1d7c0232cb8 |
| institution | Kabale University |
| issn | 2076-3417 |
| language | English |
| publishDate | 2025-08-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Applied Sciences |
| spelling | doaj-art-f64e96e4f34c4d87ad11a1d7c0232cb82025-08-20T03:35:58ZengMDPI AGApplied Sciences2076-34172025-08-011515871110.3390/app15158711Tribological Performance of Direct Metal Laser Sintered 20MnCr5 Tool Steel Countersamples Designed for Sheet Metal Forming ApplicationsKrzysztof Żaba0Marcin Madej1Beata Leszczyńska-Madej2Tomasz Trzepieciński3Ryszard Sitek4Department of Physical Chemistry and Metallurgy of Non-Ferrous Metals, Faculty of Non-Ferrous Metals, AGH University of Krakow, al. Adama Mickiewicza 30, 30-059 Kraków, PolandFaculty of Metals Engineering and Industrial Computer Science, AGH University of Science and Technology, al. Adama Mickiewicza 30, 30-059 Kraków, PolandDepartment of Materials Science and Engineering of Non-Ferrous Metals, Faculty of Non-Ferrous Metals, AGH University of Krakow, al. Adama Mickiewicza 30, 30-059 Kraków, PolandDepartment of Manufacturing Processes and Production Engineering, Faculty of Mechanical Engineering and Aeronautics, Rzeszów University of Technology, al. Powstańców Warszawy 8, 35-959 Rzeszów, PolandFaculty of Materials Science and Engineering, Warsaw University of Technology, Wołoska 141, 02-507 Warsaw, PolandThis article presents the results of the tribological performance of 20MnCr5 (1.7147) tool steel countersamples produced by Direct Metal Laser Sintering (DMLS), as a potential material for inserts or working layers of sheet metal forming tools. Tribological tests were performed using a roller-block tribotester. The samples were sheet metals made of materials with significantly different properties: Inconel 625, titanium-stabilised stainless steel 321, EN AW-6061 T0 aluminium alloy, and pure copper. The samples and countersamples were analysed in terms of their wear resistance, coefficient of friction (COF), changes in friction force during testing, and surface morphology after tribological contact under dry friction conditions. The tests were performed on DMLSed countersamples in the as-received state. The largest gain of countersample mass was observed for the 20MnCr5/EN AW-6061 T0 friction pair. The sample mass loss in this combination was also the largest, amounting to 19.96% of the initial mass. On the other hand, in the 20MnCr5/Inconel 625 friction pair, no significant changes in the mass of materials were recorded. For the Inconel 625 sample, a mass loss of 0.04% was observed. The basic wear mechanism of the samples was identified as abrasive wear. The highest friction forces were observed in the 20MnCr5/Cu friction pair (COF = 0.913) and 20MnCr5/EN AW-6061 T0 friction pair (COF = 1.234). The other two samples (Inconel 625, 321 steel) showed a very stable value of the friction force during the roller-block test resulting in a COF between 0.194 and 0.213. Based on the changes in friction force, COFs, and mass changes in friction pair components during wear tests, it can be concluded that potential tools in the form of inserts or working layers manufactured using 3D printing technology, the DMLS method, without additional surface treatment can be successfully used for forming sheets of 321 steel and Inconel 625.https://www.mdpi.com/2076-3417/15/15/8711direct metal laser sinteringfrictionmaraging tool steeltool wear |
| spellingShingle | Krzysztof Żaba Marcin Madej Beata Leszczyńska-Madej Tomasz Trzepieciński Ryszard Sitek Tribological Performance of Direct Metal Laser Sintered 20MnCr5 Tool Steel Countersamples Designed for Sheet Metal Forming Applications Applied Sciences direct metal laser sintering friction maraging tool steel tool wear |
| title | Tribological Performance of Direct Metal Laser Sintered 20MnCr5 Tool Steel Countersamples Designed for Sheet Metal Forming Applications |
| title_full | Tribological Performance of Direct Metal Laser Sintered 20MnCr5 Tool Steel Countersamples Designed for Sheet Metal Forming Applications |
| title_fullStr | Tribological Performance of Direct Metal Laser Sintered 20MnCr5 Tool Steel Countersamples Designed for Sheet Metal Forming Applications |
| title_full_unstemmed | Tribological Performance of Direct Metal Laser Sintered 20MnCr5 Tool Steel Countersamples Designed for Sheet Metal Forming Applications |
| title_short | Tribological Performance of Direct Metal Laser Sintered 20MnCr5 Tool Steel Countersamples Designed for Sheet Metal Forming Applications |
| title_sort | tribological performance of direct metal laser sintered 20mncr5 tool steel countersamples designed for sheet metal forming applications |
| topic | direct metal laser sintering friction maraging tool steel tool wear |
| url | https://www.mdpi.com/2076-3417/15/15/8711 |
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