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1. (WO2019028227) TOOL STEEL ARTICLES FROM ADDITIVE MANUFACTURING
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CLAIMS

1. A method of forming a tooling article comprising:

consolidating powder alloy into the tooling article via an additive manufacturing technique; and

heat treating the tooling article to provide the tooling article hardness of 35 to 65 HRC, wherein the tooling article is formed of an alloy composition comprising 0.2-2 weight percent carbon, 0-1 weight percent manganese, 0-1.5 weight percent silicon, 0-0.3 weight percent nickel, 0-15 weight percent cobalt, at least two of chromium, molybdenum, tungsten and vanadium in a combined amount of 5-25 weight percent and the balance iron.

2. The method of claim 1, wherein the alloy composition comprises 0.3-0.5 weight percent carbon, 0.1-1 weight percent manganese, 0.5-1.5 weight percent silicon, 2.5-6 weight percent chromium, 0-0.3 weight percent nickel, 0.2-3.5 weight percent molybdenum, 0.5-5.5 weight percent tungsten and 0.2-2.5 weight percent vanadium and the balance iron.

3. The method of claim 1, wherein the alloy composition comprises 0.2-0.6 weight percent carbon, 0.1-0.5 weight percent manganese, 0.1-0.6 weight percent silicon, 1.5-13 weight percent chromium, 0-0.3 weight percent nickel, 8-20 weight percent tungsten, 0.2-1.5 weight percent vanadium and the balance iron.

4. The method of claim 1 , wherein the alloy composition comprises 0.7-1.5 weight percent carbon, 0.1-1 weight percent manganese, 0.1-1 weight percent silicon, 3-5 weight percent chromium, 0-0.3 weight percent nickel, 3-12 weight percent molybdenum, 1-11 weight percent tungsten, 0.8-3.5 weight percent vanadium, 0-13 weight percent cobalt and the balance iron.

5. The method of claim 1, wherein the alloy composition comprises 0.6-1.5 weight percent carbon, 0.1-1 weight percent manganese, 0.1-1 weight percent silicon, 3-5.5 weight percent chromium, 0-0.3 weight percent nickel, 0-1.5 weight percent molybdenum, 10-20 weight percent tungsten, 0.5-6 weight percent vanadium, 0-15 weight percent cobalt and the balance iron.

6. The method of claim 1, wherein the tooling article exhibits elongation of at least 2% subsequent to the heat treating.

7. The method of claim 1, wherein the tooling article exhibits elongation of 3-20% subsequent to the heat treating.

8. The method of claim 1, wherein the tooling article exhibits fracture toughness of at least 2 J subsequent to heat treating.

9. The method of claim 1, wherein the tooling article exhibits fracture toughness of 5-25 J subsequent to heat treating.

10. The method of claim 1, wherein the tooling article exhibits tensile strength of 1200-2200 MPa subsequent to heat treating.

11. The method of claim 1 , wherein the tooling article exhibits tensile strength of 1900-2000 MPa.

12. The method of claim 11, wherein the tooling article has hardness of 50-60 HRC.

13. The method of claim 1 further comprising hot isostatic pressing the tooling article prior to heating treating.

14. The method of claim 13, wherein the tooling article is at least 95 percent theoretical density prior to hot isostatic pressing.

15. The method of claim 13, wherein the tooling article has hardness of 50-65 HRC.

16. The method of claim 1, wherein the tooling article is at least 98 percent theoretical density prior to the heat treating

17. The method of claim 1, wherein layers provided by the additive manufacturing technique during formation of the tooling article have individual thickness of 5 μιη to 500 μηι.

18. The method of claim 1 , wherein the powder alloy is consolidated into the tooling article via laser sintering of the powder alloy.

19. The method of claim 1, wherein the powder alloy is consolidated into the tooling article via laser melting of the powder alloy.

20. The method of claim 1, wherein powder alloy is consolidated via an organic binder and sintered to provide the tooling article.

21. The method of claim 20, wherein the tooling article has hardness of 50-60 HRC and tensile strength of 1800-2200 MPa.

22. The method of claim 1, wherein heat treating comprises annealing, hardening and at least one tempering cycle.

23. The method of claim 22, wherein peak temperature of the annealing is 850°C to 900°C.

24. The method of claim 22, wherein hardening occurs at a peak temperature of 1000°C to 1020°C followed by quenching.

25. The method of claim 24, wherein the at least one tempering cycle occurs at a temperature of 530°C to 570°C.

26. The method of claim 1, wherein the heat treating consists essentially of hardening and at least one tempering cycle.

27. The method of claim 13, the heat treating consists essentially of hardening and at least one tempering cycle.

28. The method of claim 27, wherein the hot isostatic pressing and hardening are combined into a single step.

29. A tooling article produced according to the process comprising:

consolidating powder alloy into the tooling article via an additive manufacturing technique; and

heat treating the tooling article to provide the tooling article hardness of 50 to 60 HRC and elongation of 3-15 percent, wherein the tooling article is formed of an alloy composition comprising 0.2-2 weight percent carbon, 0-1 weight percent manganese, 0-1.5 weight percent silicon, 0-0.3 weight percent nickel, 0-15 weight percent cobalt, at least two of chromium, molybdenum, tungsten and vanadium in a combined amount of 5-25 weight percent and the balance iron.

30. The tooling article of claim 29, wherein the alloy composition comprises 0.3-0.5 weight percent carbon, 0.1-1 weight percent manganese, 0.5-1.5 weight percent silicon, 2.5-6 weight percent chromium, 0-0.3 weight percent nickel, 0.2-3.5 weight percent molybdenum, 0.5-5.5 weight percent tungsten and 0.2-2.5 weight percent vanadium and the balance iron.

31. The tooling article of claim 29, wherein the alloy composition comprises 0.2-0.6 weight percent carbon, 0.1-0.5 weight percent manganese, 0.1-0.6 weight percent silicon, 1.5-13 weight percent chromium, 0-0.3 weight percent nickel, 8-20 weight percent tungsten, 0.2-1.5 weight percent vanadium and the balance iron.

32. The tooling article of claim 29, wherein the alloy composition comprises 0.7-1.5 weight percent carbon, 0.1-1 weight percent manganese, 0.1-1 weight percent silicon, 3-5 weight percent chi mium, 0-0.3 weight percent nickel, 3-12 weight percent molybdenum, 1-11 weight percent tungsten, 0.8-3.5 weight percent vanadium, 0-13 weight percent cobalt and the balance iron.

33. The tooling article of claim 29, wherein the alloy composition comprises 0.6-1.5 weight percent carbon, 0.1-1 weight percent manganese, 0.1-1 weight percent silicon, 3-5.5 weight percent chromium, 0-0.3 weight percent nickel, 0-1.5 weight percent molybdenum, 10-20 weight percent tungsten, 0.5-6 weight percent vanadium, 0-15 weight percent cobalt and the balance iron.

34. The tooling article of claim 29 having fracture toughness of 5-25 J subsequent to the heat treating.

The tooling article of claim 29 having tensile strength of 1900-2200 MPa.