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<p>During hot forming processes of metal alloys, tools are exposed to high temperatures. The presence of high temperatures promotes accelerated tool wear, generating additional costs. Commonly used tool materials are hot-work steels. However, even these materials are subject to tempering and deterioration due to high temperatures. Lowering the working temperature of tools through the use of cooling channels is a promising technology for improving their service life. However, obtaining cooling channels with complex shapes is a significant challenge. In this research, we demonstrated a new technology for constructing cooling channels for tools used in hot-forming processes. Smooth, circular cooling channels made of straight stainless steel tubes (of potentially varying shapes) were welded using the Cold Metal Transfer technology to a hot-work steel substrate. These channels were then encased in hot-work steel using a hardfacing process. The studies demonstrated complete fusion of both materials, minimal weld defects, and high hardness of the hardfacing layer. This method can enable the construction of hot-work tools with standard mechanical properties and improved heat dissipation, thus extending tool service life.</p>

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Innovative additive manufacturing approach to 3D printing conformal cooling channels for hot forging dies

  • 期刊论文

  • 发表日期：

    2026年1月7日

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  • Paweł Widomski,
  • Artur Lange,
  • Paweł Kustroń,
  • Marcin Kaszuba,
  • Daniel Dobras,
  • Michał Kołodziński

摘要

During hot forming processes of metal alloys, tools are exposed to high temperatures. The presence of high temperatures promotes accelerated tool wear, generating additional costs. Commonly used tool materials are hot-work steels. However, even these materials are subject to tempering and deterioration due to high temperatures. Lowering the working temperature of tools through the use of cooling channels is a promising technology for improving their service life. However, obtaining cooling channels with complex shapes is a significant challenge. In this research, we demonstrated a new technology for constructing cooling channels for tools used in hot-forming processes. Smooth, circular cooling channels made of straight stainless steel tubes (of potentially varying shapes) were welded using the Cold Metal Transfer technology to a hot-work steel substrate. These channels were then encased in hot-work steel using a hardfacing process. The studies demonstrated complete fusion of both materials, minimal weld defects, and high hardness of the hardfacing layer. This method can enable the construction of hot-work tools with standard mechanical properties and improved heat dissipation, thus extending tool service life.