Printable die steels for additive manufacturing

Abstract

A novel family of die steels is disclosed. This family of die steels is strengthened through the formation of M2C precipitates and one or two additional precipitates, wherein M is one or more of chromium (Cr), vanadium (V), molybdenum (Mo) or tungsten (W). These additional precipitates may include copper precipitates, NiAl precipitates, and Ni (Al1-xMnx) precipitates. This creates a steel having an acceptable hardness, as well as excellent thermal conductivity.

Description

[0001] Printable Die Steels for Additive Manufacturing

[0002] This application claims priority of U.S. Provisional Patent 5 Application 63 / 637,364, filed August 27, 2024, the die closure of which is incorporated herein by reference in its entirety.

[0003] Statement of Government Support

[0004] 10 This invention was mace with government support under

[0005] 7 ONANB' 7H 005 awardee by the National Institute of Standards and Technology. The government has certain rights in the invention.

[0006] Background

[0007] 15

[0008] High-pressure die casting, injection molding, and presshardening are primary scaping or secondary forming technologies for industrial i.ass production. In these processes, a mold including TWO die halves is ma ch. incd to shape the c>'<ponor.~ s . The 20 die half irself again is subdivided into several die inserts . The interior surfaces of these die inserts represent the part to be fabricated. The ale halves are pressed together, and molted material is injected into the enclosed volume, or sheet material is formed.nhe injected or formed material is then cooled while 25 within the mold. Cnee cooled, the die halves are separated so that the car: may be reroved.

[0009] The traditional process of creating a die insert is very time consuming. Furthermore, traditional processes limit the freedom of 30 the design ■:? " rhe die insert.

[0010] D340812817 / 36 27.06.2025 FAX - Jun-2625 22:55 floheng@gnail.com PCT / DE2025?&(^073

[0011] Consequer.dy , tr.e use of additive manufacturing to fabricate these die inserts for high product ion processes is very at~r active . Additive manufacturing allows a high degree of design freedom and is very cost effective for small quantities, for fabricating a

[0012] 5 metal component, laser oowder bed fusion (LPBF) is typically used. Ths L.PBT printing technique may be characterized as a multi -pass, micro-welding technique. Therefore, welding challenges exist when utilizing additive manufacturing. Conventional CrMc:v^rQt-war king die B tools (such as .110, Illi, Hid) .possess a carbon content of

[0013] 10 approximately C.25 wt.-% to 0.6 ,wt.-%, re suiting in a poor weldability, arid consequent 1 v, poos LPBF print ahi liny. Often, hot ano cold cracking occurs ~sing medium oaf bon CxMoV-hot working die steels for LPDT printing, particularly at industry relevant component sizes.

[0014] 15

[0015] As a substitute for the conventional Crffcv die steels in the context of die insert LPBF-prir.ting, low carbon and high Ki- containing maraging steels have beer, explored. These types of st epl possess excellent. printabil ity. Specifically, their mait

[0016] 20 strengthening mechanism is contributed by precu.pl tat ion . Hov'evon, unlike convenvionai CrMcV-die steels which relv on carbide precipitates, Ni-ccntaining mar aging steels utilize ir~ a me tai lie NidTi- ano. Ni Al -type precipitates. However, these maraging steels possess a significant disadvantage: due to the high solid solution

[0017] 25 elements (mainly Mi 17 wt.-% and Co 10 wt.-%, 1 the thermal conductivity of rhe maraging steel is drastically reduced, potentially leading to increased thermal stresses at the die insert surface and finally premature failure. Moreover, aspects such as reverted austenite transformation, as well as mission or sticking

[0018] 30 of Al -al lev molt, are problematic in the context of high pressure die caszing.

[0019] 2

[0020] D340812818 / 36 27.06.2025 FAX - Jun-2625 22:56 floheng@gnail.com PCT / DE2025?&(^073

[0021] Consequently, there is a great need to develop novel hot- working die steels that are tailored for additive manufacturing, and specifically, laser powder bed fusion. Additionally, io would be beneficial if this die steel had a thermal conductivity that 5 allows prolonge? operatic" and reduced cycle times in high pressure die casting and inject lor. noising processes.

[0022] Summary

[0023] 10 A no-zel family of die steels is disclosed. This family of die steels is strengthened through the formation of MjC precipitates and one on two additional precipitates, where.). n M is one or more of chromium (Cr) , vanadium (V) , molybdenum (Mo) or tungsten (TN) . These nddl f Iona. I precipitates may include copper pi eel ps i.ates , 15 Nih I precipitates, and Ni (A.„i-xMnK) precipitates. This creates i steel having an acceptable wardress, as well as excellenr “hermal conductivity.

[0024] According to ore embodiment , a method of producing a steel is

[0025] 20 disclosed. The method comprises form ng a powder mjxture comprising iron (Fa) , carno~ (C) , nickel (Fi ; , aluminum (Al) , and M, wherein M is one or more of chromium (Or) , vanadivfn (Vi , molybdenum (Ito) , tungsten (W) , tantalum (Ta) , zirconium (Zr) , or niobium (Nc) ; using laser powder bed fusion to heat the powder

[0026] 25 mixture to fo*m rhe steel , wherein the steel comprises at le = st two precipitates, a fins I precipitate comprising M?C; and a second precipitate comprising a. niche I -al uninum (Ni-Al) rich precipitate. In sone embodiments, a carton weight percentage of the powder mixture is between O.G4% and 0.2%. In some onbodim.ent s , a nickel

[0027] 30 weight percentage cf the oowder mixture is less than 20%. In some embodiments, the powder fixture ^urther comprises manganese (Mn) to facilitate fcrxatlcn of the second precipitate. In certain

[0028] D340812819 / 36 27.06.2025 FAX - Jun-2625 22:56 floheng@gnail.com

[0029] PCT / DE2O25?&(30O73 embodiments, the second precipitate comprises Mi (Ali-xMhz) . In certain embodiments, a weight o ere enrage of manganese and aluminum in the powder mixture is such that a combined atomic percentage of Mn arid Al is equal to an atomic percentage of nickel.

[0030] 5

[0031] In come embodiments, titanium and nitrogen are added during gas atonizaiion of the powder mixture co allow precipitate strengthening. In some embodiments, a nitriding treatment is per formed after the steel is formed to increase surface hardness 10 by forming al un.ir.um. nitride at an outer surface.

[0032] In some embodiments, tr.e powder mixture further comprises copper, ana tee steel comprises Three precipitates, wherein a thira precipi .ate co:r.p r res a copper rich precipitate. Tn certain 15 embodiments, a weight percentage of the copper in the powder mixture is uc to 15% . In seme embodiments, the powder mixture further comprises manganese (Mn) :o facilitate formation of the second precipitate. In certain embodiments, the second precipitate comprises Mi (Al i <Mnx) • Tn certain embodiments, a weight percentage 20 of manganese and alumintm in the powder mixture is such that a combined atomic percentage of Mn and Al is equal to an atomic percentage of nickel.

[0033] According to another embodiment, a steal made using laser powder 25 bed fusion, :.s disci used . lire steel comprises iron; and two precipitates, wherein a first precipitate comprises M?C, wherein M is one or more of ccrcrnium (Cr) , vanadium (V) , mo lybdenum (Moi, tungsten (W) , nantdltm (Th ) , zirconium (Zr) , or niobium (Nb) ; and a second precipitate comprises a nickel. -aluminum (Ki -Al) rich. 30 precipitate . In some emcodimer.cs, a carbon weignt porcsr.rago of the powder mixture is between 0.01% and 0.2%. In some embodiments, a ' -l .l weight percentage of the powder mixture is less than 20%.

[0034] D340812820 / 36 27.06.2025 FAX - Jun-2625 22:56 floheng@gnail.com PCT / DE2025?&(^)073

[0035] In sene embodiments, the steel further comprises manganese (Mn) to facilitate formation, of the second precipitate . In certair embodiments , the second precipitate comprises Ni (Ali-yin*) .

[0036] 5 According to another enbcdiment, a steal made using Isser powder beu iiiEior is dlsidrsed. The steei comprises iron; an<1 three precipitates, wherein a first precipitate comprises XiC, wherein M is one or mode of chrcmiun (Cr) , vanadium (V; , molybdenum (Mo) , tungsten (W) , tantalum (Ta) , zirconium (Zr)ror niobium (Kb) ; a 10 second precipitate comprises s nickel -aluminum (Ni-Al) rich precipirate; and a third precipitate comprises ~ copper rich precipitate. In some eruuodi tr.etxsra carbon weight percentage of the powder mixture is between 0.04% sne 0.2%. In some embodiment sfa nickel weight percentage of the powder mixture is Jess' than 20%.

[0037] 15 Tn sene embodiments, the steel further comprises manganese (Mn) to facilitate formation of the second precipitate. In certair. embodiments , the second precipitate comprises Ni"(Ali-KMn:.<) - In some embodiments, a copper ’weight percentage is less uh an 15%. In seme embodiments, a thermal ccriducul v ii: y of the steel is greater than 20 25h / mK.

[0038] According to another embodiment, a powder mixture is disclosed. The pewder mixture comprises iron (Fa) ; carbon (C) ; nickel (Ni ) ; aluminum. (Al) ; and X, ’wherein M is one or acre cf chromium (Cr) , 25 vanad i ur (V) , molybdenum (Mb) , tungsten (W) , tantalum (la) , zirconium (Zr) , or niobium (Kb) ; wherein a carbon weight percentage of t?.e powcer mixture is between 0.34% arcs 0.2% and a nickel weight percentage of ~.hc powder mixture is less, than 20%, in some embodiments, the powder mixture further comprises manganese (Mn) . 30 In certain embodiments , a weight percentage of manganese and

[0039] • j . j'r n . f ir. die powder mixture is such rhat a combi red atomic percentage of >ki and Al is equal to an atoxic percentage of nickel.

[0040] D340812821 / 36 27.06.2025 FAX - Jun-2625 22:57 floheng@gnail.com PCT / DE2025?&(3§073

[0041] According to another embodiment, pcwde r mix~ ur e disclosed.

[0042] Th© powder nixture comprises iron (f'e) ; oar box (G) ; nickel (hi,') ; aluminum (AL) ; copper (Cu) ; and M, wherein M is we or more of chromiuT (Ct), vanadium (V) , mo’ ybdenum (Mo) , tungsten (tf)ftantalum (Ta) , zirconium (Zr) , or niobium (Kb) ; wherel / i a c arbor, weight percentage of the powder mixture is between 0.04% and 0.2%, nickel weight per cent ace of the powder mixture is Less than 20% and a copper weight percentage of the powder mixture is T5% or

[0043] 10 less. In some enbodiinen us , Lhe cowdcr mixture further comprises manganese iMn) . In certain embodiments, a weight percentage of manganese aid aluminum, in the powcer mixture is such that a combined atomic percentage of Mn ana Al is equal to an atomic percentage of nickel.

[0044] Brief Description of the Drawings

[0045] 20 For a better understanding of the present, disclosure, reference is mode to the accompanying drawings, in which li ke elements are referenced wit?, like numerals, and in which:

[0046] FIG, 1 shows a Graville diagram. for determining susceptibility to HAS cracking in plate seeds;

[0047] 25 FIG. 2 shews the crystal structure of the various preci pi _a tes;

[0048] FIG. 3 shews .in exemplary die insert;

[0049] FIG, 4 shows a comparison of the present steel with other traditional, steels;

[0050] 30 FIG. 5 shows oho ductility of the present steel;

[0051] FJ G. 6 shows the chern’.al conductivity of the present steel with other tradition a... steels; and

[0052] D340812822 / 36 27.06.2025 FAX - Jun-2625 22:57 floheng@gnail.com PCT / DE2025?&(^073

[0053] FIG. '! shows a transmission electron microscopy image of the present steel ~ emper-s-d at 550 "C for £ hours.

[0054] Detailed Description

[0055] As noted above, additive manufacturing for metals typically utilizes a laser powder bed fusion (LK!ij process, which involves 10 a plurality of micro-wsids. Additionally, it is commonly known that, to avoid welding issues, the maximum carbon content of the die steels should :;e about 3.2 wt-% or less. This is demonstrated in FIG. 1, which is a Graviiie diagram for determining susceptibility to heat affectsd zone fHAZj ciacd ng in plate 15 steels. Thus, to create a die steel chat may utilize the LPBF process, the amount of carbide strengthening is reduced compared to conventional CrMoV die steels. However, these metal carbides allow a major component of strengthenings.

[0056] 20 To compensate for this reduction ca re j de strengthening, other precipitates, in addition to M2C preci pirates, are needed.

[0057] Thus, the present die steel utilizes in tor rr.et allic NiAl-cicn precipioates . NiAl rich phases precipitate as Ez-tvpe or Hsusler- 25 phase. In order to promote the precipitation ot K 1A1 phases, manganese can be adder, to fvcm Ni (Alx-xMr:,x) . Note that the composition of the die steel is such that Ni3'?‘,l preci pi tates are not formed, as r.hese precipitates lower the Thermal conduc" ivi ty of the material.

[0058] 30

[0059] As a third strengthening precipitate, Cu-rich precipitates may ue integrated to achieve the requisite hardness. The Cu-

[0060] D340812823 / 36 27.06.2025 FAX - Jun-2625 22:57 floheng@gnail.com PCT / DE2025?&(38073 precipitates initially possess an oCC-crystal structure that later can transform “o FCC.

[0061] FIG. shows Lhc structure of these various p recipl rates .

[0062] Thus, in soie embodiments, the die steel includes M>C and MiAl-rich precipitates, which may be NiAl or Ni !'Al^_xXnxi. In other embodiments, the die steel also includes Cu-rich precipitates, furthermore, additional Crain refiners, such ss nitrides, oxides, carbides, a"d borides, may be added for additional strength, isotropic material behavior, and not cracking prevention. Grain refiners may be adoed ir.situ curing gas atomization ( late-stag e addition to the crucib.le, crucible atmosphere or via dispersing

[0063] 15 gas) or mechanical al oying or chemical surface modification.

[0064] FIG, 3 shews a dis insert created using '1EEF printing with a composition of 0.10% C; 0.85% Xo; 1.6% W; 3.4% Cu; 0.85% Al; 1.50% Mn; 3.1% Ni; 0.35% Ti; and 0.1% N. Note that all percentages are 20 expressed as weight percentages. This die is referred to as doper Die in FIGs . 4-6.

[0065] In FIG, 4, the vortical axis shows the hardness of the air steel, as measured in Vickers. The horizontal axis shows the 25 tempering temperature. This graph shows die performance of maraging steel (M300) , CrMoV steel (H13) and the die steel shown in FIG. 3, wrier was fabricated using additive m.inufn ctu ri ng . Note that while the hardness is slightly less than the maraging steel and toe CrMoV steel at tsnperatur? above 475r‘G, the hardness of 30 the present die steel is asave 400 Vickers up to a terpc zinc temperazure of 550nC, which is typically acceptable for most ap.pl ica :i ons .

[0066] D340812824 / 36 27.06.2025 FAX - Jun-2625 22:58 floheng@gnail.com PCT / DE2025?&(3S073

[0067] FIG. 5 shows rhe Chatty Impact energy of the ore sent die steeu, mat cat mg excellent ductility Q~ the ma terra— .

[0068] 5 Further, FIG. 6 shows the thermal conductivity of these three die. steels at 450°C. Kobe I h a t Hie prettnl die steel has a thermal conductivity that is r.ear.y 9W / mK greater that CrMoV de steel and nearly 14 W / mK greater than maraging steel.

[0069] 10 Compared tc conventional die steels, the tempering resistance and peak hardness cF the present die steel is reduced. Yeh, the high thermal conductivity of the present die steel leads to reduced thermal stresses ir. nigh pressure die casting and injection molding a ppi lea \. tons -

[0070] 15

[0071] Using transmission electron microscopy, the present die steel was analyzed in the tempered condition (3550C for 6 hours) . As shown in FIG. 7, the three precipitates may be identified via olmimin nspping .sing energ v-oi sper si me X-rev

[0072] 20 tipectrosecpy (ZDS -mapping) . The rcd-s;.ape precipitates correspond tp M2C carbides mhich correlates with v.he presence of Molybdenum and Tungsten enrichment and may be seen in images all I and C.VII, respectively, Trie spherical NiAlMn-precipicates may also be detected in images cIV, eV and cVI . Lastly, the Cu-prc Pipit a tes

[0073] 25 can be identified as single precipitates or ocme-sheU pari / icles (see image ell) with the KlALMn -precipitate as ^ell as coprecipitate of t.'.e 1420 caroides.

[0074] While F ICs . 4-6 utilize a steel having a specific oarposition,

[0075] 30 the disclosure is not limited to this embodiment . Rather, the various elereres may be present in a range of percent ages .

[0076] D340812825 / 36 27.06.2025 FAX - Jun-2625 22:58 floheng@gnail.com PCT / DE2025?&(^073

[0077] For example, the amount of carbon may be maintained at between 0.04 wt-% and 0.2 wt-l. Ccnsecuently, the total amount of M is defined as being greater than twice the atomic perteunagc cf carbon. In other words, if C.2 wt-% of carbon results in a 0.4C 5 at-% of the die steel, the total amount of M wi 11 bs greater than 1.8 at-%. Tais is to ensure all carbon is transformed from brittle Feat- into Xrt. in certain embodiments, M is one or xore cf chromium (CL) ,

[0078] 10 vanadiux (V) , moLybden_.ru (Mo) or Lungs ten (W) . Alternatively, other transition elerexts such as tantalum, zirconium, and / or niobium may be used as the M material. Moreover, ch rural urn may be a deed to increase rhe corrosion resistance of the die steel up to 13 w li .—% J

[0079] 15

[0080] In addition, to maintain adequate thermal conductivity, the amount of nickel may be maintained at loss than 20,0 wt— ' S, _n other embodiments, the amount cf nickel may be <e.intaine-d at less than 10.0 w t - % .

[0081] 20

[0082] Thus, in one embodiment, the die steel nay be formed from h powder mixture having the following elements in the following amounts :

[0083] 25 • Carbon (cetweer. 0.04 and 0.2 wt.-%) ;

[0084] • One or lore of M (which is Or, V, Mo, W) at more than twice the at • -% of carbon;

[0085] • Ni (1-20 wt. -%) ;

[0086] • Al (0.5-4.0 wt.-%) up Lo the at.-% of nickel; and

[0087] 30 •rihe remainder as Fe .

[0088] D340812826 / 36 27.06.2025 FAX - Jun-2625 22:58 floheng@gnail.com PCT / DE2025?&(^073

[0089] This powder mixture is then subjected to a laser powder red fusion additive nranu f act vr ir.q process to crea~e the steel.

[0090] This die steel may be referred to as l&C-MiAl die steel

[0091] 5 throughout this disclosure due to the two precipitates that are generated. With a nickel concentration of 20 wt-B, a thermal conductivity of 24W / mK may be achieved. Ac a nickel concentration of 10 wM, the thermal conductivity nay be greater chan lOWmK.

[0092] 10 Further, manganese (Mr.) may be included in Lhe powder mixture to facilitate the precipitation of NiAl during the welding process. Tn some embodiments , the amount of Mn may be approximately the same at . -% as aluminum. In other embodiments , the combined atomic percentages cf manganese &ad aluminum may be eq^al Lu the atomic

[0093] 15 percentage of nickel. The addition of manganese results in a die steel having M2C and Ki (Ali-xMhx) precipitates .

[0094] Further, in certain embodiments, a steel having three preciplcaf.es nay be created, ir th" s embodiment, to increase the

[0095] 20 thermal conductivity, copper may be added to the powder mixture, at levels ng to 15.0 wt-ft. This allows the die • to achieve 1 thermal conductivity of greater than 35W / mK. None that copper why be added to a powder mixture that includes manganese or does not include manganese. Note chat when copper is added, the amount of

[0096] 25 al urn nut, nickel and manganese may be reduced, as the copper preml pi ,=ter serve co in crease both thermal conductivity and strength .

[0097] In addition, to allow precipitace strengthening and grain

[0098] 30 refinement, the ins itu-pr ecipit at ion of titanium -nitrides (TiN) during gas atomization of the ponder mixture may he iuclwded, leading to a grain refinement in the LPBF-crinted die steels. Thus,

[0099] D340812827 / 36 27.06.2025 FAX - Jun-2625 22:59 floheng@gnail.com PCT / DE2025?&(^073 titaniur and nitrogen may also be added tc the ponder mixture during gas atomization, if desired. The amount of riraniua- and nitrogen may be up to 5 wt-% . _n other eiribcdiu.&u.~ s , the amounts may be much less, such as less than 2 wt-%. Alternatively or 5 additionally, dif ferent grain refiriers, such as other nitrides, oxides, caroid.es or borides tnav be used.

[0100] Additionally, after formation , rhe present die steel may undergo a nitriding treatment to increase the surface hardness by 10 al .1.1 nuu-ni Irides (AIN) . The nitrogen bonds with al urii riuiu near the surface of the die to create aluminum nitrides. While the depth of these aluminum Nitrides may be relatively shallow, the increase (in surface hardness nelps realise erosion and wear during high pressure die casting aid injection noi.ait.g applications.

[0101] 15

[0102] The present system has many advantages. The steel described herein may be made using LTBE process, allowing lower cert creation of die casts. Note that in other embodiments, other additive manufacturing rrocsHsew such as wire are manufacturing, electron 20 bean melting cr binaer: jetting ray oe usea with this powder. Further, when all three precipitates are included, the themal conduct ivity may be 35W / rt< or more, which far exceeds tout achieved lay maraging steel of CrMoV steel .

[0103] 25 The present disclosure is nor to oa limited In scope by the

[0104] Specific embodiments described herein. Indeed, other various embodiments of and modi f i cartons to the present di sclosure, in addition to those described herein, will he apparent to “hose of ordinary skill in the art from the foregoing descript ion and

[0105] 30 accompanying drawings. Thus, such other embodiments and modifications are intended to fall within the scope of the present disclosure. Further, a ..though the present disclosure has beet

[0106] D340812828 / 36 27.06.2025 FAX - Jun-2625 22:59 floheng@gnail.com PCT / DE2025?&(^073 described herein in the context of a particular imp! emena a~ion in a particular environment for a particular purpose, those of ordinary skill in the art will recognize chat its usefulness is not limited therdub and that the present disclosure may be 5 beneficially implemented in =nv number of environments for any number of purposes. Acccrci.ngly, be claims set lilerth below should be construes in view of rhe full breadth and soirit of the present disclosure as described herein.

[0107] D340812829 / 36 27.06.2025 FAX

Claims

7- Jun-2625 22:54 floheng@gnail.com PCT / DE2025?&(^073What is cl a imed i s :

1. A method of producing a steel, comprising: forming a powder mixture comprising iron (Fcj , carbon (C) , nickel (Ni J , aluminum (Al) , and M, wherein M is one 5 or more of chromium (Cr) , vanadium (Vi , molybdenum (Mo), tungsten (W) , tar.r&lui. (Ta) , zirconium (Zr) , or niobium (Nb) ; using laser powder bed fusion to heat "life powder uixtvre tc form the seed, wherein the steel comprises ac least10 t wo precipl Lates , s. fi'-'su precipitate comprising Mat; and a second precipitate cowprising a nickel -aluminum (Ni-Ai) rich precipitate.15 z. The rnetr.od of claim 1, wherein a carbon weight percentage of rhe oowder mixture is between 0.04% and 0.2%.

3. The method of claim 1, wherein a nickel weight percentage of rhe rood e" mixture is loss than 20%.

204. The met nod Of claim 1, wherein rhe powder mixture further comprises manganese (Mn) to i’icili";ite formation of the second precipitate, and whore in the second precipitate comprissE Ni (All Mui .

255. The method of claim 4, wherein a weight percentage of manganese and aluminum in the powder mixture is such that a combined atomic percentage of Mn and .Al is equal to an atomic percentage of nickel.30 40812814 / 36 27.06.2025 FAX7- Jun-2625 22:55 floheng@gnail.com PCT / DE2025?&(^0736. The me trod of claim 1, where titanium and nitrogen are added during gas atomization of the powder sixfure ~o allow pr ccipic ate strengthening,5 7. The method of claim 1, wherein a nitriding rreatment is rer Tc med after the slee! is formed to inerease surface hardness by terming aluminum nitride at an outer surface.

8. 1'hc method of claim 1, wherein rhe powder mixture further10 compriios cooper, and Lhe stool comprises three prccipr Lates , wrier sir a thlrc precipitate oerprises a copper rich precipitate.St. The method of claim 8, wherein a weight percentage of rhe copper in the powder mixture is up to ,15%.1510. The method cf claim 8, wherein the nowder fixture further comprises nang^r.esc (Mn) to facilitate formation of the second precipitate and wherein the second precipitate comprises di (All-2011. The method of claim 10, wherein a weight percentage of manganese and aluminum in the pewder mixture is such that a combined anomic percentage of Mn and Al is equal to an atomic oercantage of nickel.2512. The steel producer using L c- method of any of claims 1-11.30 40812815 / 36 27.06.2025 FAX7- Jun-2625 22:55 floheng@gnail.com PCT / DE2025&&J07313. A powder mixture, suitable tor laser powder bed fusion, comprisi ng : iron (be) ; carban (C) ;5 nickel (Ni) ; aluminum (Al) ; andM, wherein M is one or more of chromium (Cr) , vanadium (V)rmolybdenum (Mo), tungsten (W) , tantalum (Ta) , zirconium (Zr) , or niobium. (No) ;10 wherein a carbon weight percentage of the powder mixture is between C .04 % and 3.2% and a nickel weight percentage of the powder mixture is less that. 20%.

14. The powder mixture of cl. aim 13, further comprising manganese15 (Mr; .

15. The powder mixture of claim 14, wherein a weight percentage of manganese and aluminum in the powder mixture is such that a combined anomic percentage of Mn and Al is equal to an atomic20 percentage of nickel.

16. The powder mixture of claim 13, further comprising:wherein a coppar weight percentage of the oowder mixture is25 15% or less. 40812816 / 36 27.06.2025 FAX

Images