| Abstract Scope |
The U.S. defense industry heavily relies on forged components for their superior yield strength, precision, and wear resistance. Forging dies shape ingots or preforms under intense cyclic loads, but harsh conditions lead to heat fatigue, cracking, and wear, eventually causing die failure and production delays. This work introduces arc-based Direct Energy Deposition (Arc-DED), an innovative and cost-effective method for repairing these damaged forging dies. Four wire-based repair alloy materials, including iron-based Eureka 450, cobalt-based Eureka MF201 (Satellite type), and nickel-based Inconel 718 and Eureka CWD (Waspaloy type), were applied on H13 tool steel die substrates. Comprehensive microstructural characterization, X-ray radiography, microhardness profiling, and mechanical testing validated a strong metallurgical bonding and a reduced HAZ compared to conventional welding. The notable spike in hardness near the interface was observed due to untempered martensite from rapid cooling. Nickel based repair alloys demonstrated superior toughness and ductility owing to their stable austenitic matrix. |