| Abstract Scope |
Binder jetting offers a scalable route for manufacturing geometrically complex AISI M2 tool-steel components, but residual porosity and heterogeneous carbide networks limit performance after sintering. This work examines how binder chemistry, sintering temperature, cooling rate, and hot isostatic pressing (HIP) govern densification, carbide evolution, and compressive behavior. HIP increased relative density from approximately 93–95% to above 99% and promoted diffusion-assisted redistribution of W, Mo, and V, transforming nonuniform carbide networks into finer MC, M₂C, and M₆C distributions. The optimum FluidFuse condition, sintered at 1270 °C for 60 min and furnace cooled before HIP, achieved approximately 99.7% density, 855 HV hardness, 4130 MPa compressive strength, and 24% strain. The work will further compare binder jetting-HIP with laser powder bed fusion and directed energy deposition, emphasizing differences in defect formation, carbide morphology, anisotropy, hardness, and compressive performance. The study establishes processing pathways for selecting additive routes for high-performance tooling and die applications. |