Laser Powder Bed Fusion has become a widely recognized AM process for metals over the last years as it enables the production of complex shaped components. Until now the range of processable alloys is limited to low carbon steels. High-carbon tool steels tend to cracking and warping. Despite high potential, the alloy development is costly and time-consuming because of expensive atomization and long lead times for powder. The Laser Powder Bed Alloying (LPBA) allows a more flexible approach of alloy design through the usage of powder blends from conventionally available powders.
High alloyed cold work tool steels with sufficient chromium solved in the metal matrix achieve high wear- and corrosion resistance as required in certain cutting and forming applications. In this study, X40CrMoV5-1 has been modified by Cr3C2 and elemental Cr to achieve comparable mechanical properties to conventionally manufactured X105CrMo17 for this application. The novel alloy was thermodynamically modelled, processed crack free by LPBA and has undergone in-depth microstructural investigations in different heat treated states. A martensitic steel with Cr-rich carbides and Cr-rich inclusions was generated. The microstructural influence on the wear and corrosion properties was characterized and analyzed by ASTM G65 abrasive wear tests and potentiodynamic polarization curves.