M2 Powder

M2 is a high-speed steel powder characterized by its high hardness and wear resistance along with good toughness and compressive strength. It is widely used in metal additive manufacturing to produce durable tooling for cutting, forming and stamping applications.

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M2 is a high-speed steel powder characterized by its high hardness and wear resistance along with good toughness and compressive strength. It is widely used in metal additive manufacturing to produce durable tooling for cutting, forming and stamping applications.

Composition of M2 Powder

The composition of M2 high-speed steel powder is:

Element Weight % Purpose
Tungsten 6.0 – 6.8 Hardness, wear resistance
Molybdenum 4.8 – 5.5 Toughness, strength
Chromium 3.8 – 4.5 Hardening, wear resistance
Vanadium 1.9 – 2.2 Hardening, wear resistance
Carbon 0.78 – 0.88 Hardening
Manganese 0.15 – 0.45 Hardening
Silicon 0.15 – 0.45 Deoxidizer

The high tungsten, molybdenum and chromium content impart excellent hardness and wear resistance.

Properties of M2 Powder

Key properties of M2 powder include:

Property Description
Hardness 64 – 66 HRC when heat treated
Wear resistance Excellent abrasion and erosion resistance
Toughness Higher than tungsten carbide grades
Compressive strength Up to 300 ksi
Heat resistance Can be used up to 600°C
Corrosion resistance Better than plain carbon steels

The properties make M2 suitable for durable cutting, stamping and forming tooling.

AM Process Parameters for M2 Powder

Typical parameters for printing M2 powder include:

Parameter Typical value Purpose
Layer height 20-50 μm Resolution versus build speed
Laser power 250-500 W Sufficient melting without evaporation
Scan speed 400-1200 mm/s Density versus production rate
Hatch spacing 80-120 μm Mechanical properties
Support structure Minimal Easy removal
Hot isostatic pressing 1160°C, 100 MPa, 3 hrs Eliminate porosity

Parameters tailored for density, microstructure, build rate and post-processing requirements.

Applications of 3D Printed M2 Tooling

AM fabricated M2 components are used for:

Industry Tooling applications
Automotive Stamping dies, forming tools, fixtures
Aerospace Jigs, fixtures, trim tools
Appliances Punches, blanking dies, bending dies
Consumer goods Injection molds, stamping dies
Medical Cutting tools, rasps, drill guides

Benefits over traditionally processed M2 tooling include complexity, lead time and cost reduction.

Specifications of M2 Powder for AM

M2 powder must meet strict specifications:

Parameter Specification
Particle size range 15-45 μm typical
Particle shape Spherical morphology
Apparent density > 4 g/cc
Tap density > 6 g/cc
Hall flow rate > 23 sec for 50 g
Purity >99.9%
Oxygen content <300 ppm

Custom size distributions and controlled moisture levels available.

Suppliers of M2 Powder

Reputable M2 powder suppliers include:

Supplier Location
Sandvik Osprey UK
Carpenter Additive USA
Erasteel Sweden
Hoganas Sweden
LPW Technology UK

Prices range from $50/kg to $120/kg based on quality and order volume.

Handling and Storage of M2 Powder

As a reactive material, careful M2 powder handling is essential:

  • Store sealed containers away from moisture, sparks, ignition sources
  • Use inert gas padding during transfer and storage
  • Ground equipment to dissipate static charges
  • Avoid dust accumulation through extraction systems
  • Follow applicable safety precautions

Proper techniques ensure optimal powder condition.

Inspection and Testing of M2 Powder

Quality testing methods include:

Method Parameters Tested
Sieve analysis Particle size distribution
SEM imaging Particle morphology
EDX Chemistry and composition
XRD Phases present
Pycnometry Density
Hall flow rate Powder flowability

Testing per ASTM standards verifies powder quality and batch consistency.

Comparing M2 to Alternative Tool Steel Powders

M2 compares to other tool steel alloys as:

Alloy Wear Resistance Toughness Cost Ease of Processing
M2 Excellent Good Medium Fair
H13 Good Excellent Low Excellent
S7 Excellent Fair High Difficult
420 stainless Poor Excellent Low Excellent

With its balanced properties, M2 supersedes alternatives for many wear-resistant tooling applications.

Pros and Cons of M2 Powder for Metal AM

Pros Cons
Excellent hardness and wear resistance Lower toughness than cold work tool steels
Good heat resistance and thermal stability Required post-processing like HIP and heat treatment
Established credentials for metal AM Controlled atmosphere storage required
Cost advantage over exotic tool steels Difficult to machine after printing
Properties match conventional M2 Limited corrosion resistance

M2 enables high wear resistance additive tooling, though not suitable for highly corrosive environments.

Frequently Asked Questions about M2 Powder

Q: What particle size range works best for printing M2 powder?

A: A typical range is 15-45 microns. It provides optimal powder flowability combined with high resolution and dense parts.

Q: What post-processing methods are used for M2 AM parts?

A: Hot isostatic pressing, heat treatment, surface grinding/EDM, and shot peening are typically used to eliminate voids, harden, and finish parts.

Q: Which metal 3D printing process is ideal for M2 alloy?

A: M2 can be effectively printed using selective laser melting (SLM), direct metal laser sintering (DMLS) and electron beam melting (EBM) processes.

Q: What accuracy and surface finish can be expected for M2 printed parts?

A: Post-processed M2 components can achieve dimensional tolerances and surface finish comparable to CNC machined M2 tooling.

Q: What industries use additively manufactured M2 tooling components?

A: Automotive, aerospace, medical, consumer goods, appliances, and industrial sectors benefit from 3D printed M2 tooling.

Q: What is the key difference between M2 and M4 grades of high speed steel?

A: M4 has slightly lower vanadium and molybdenum content leading to a better combination of wear resistance and toughness compared to M2.

Q: Does M2 require support structures when 3D printing?

A: Minimal supports are recommended on overhangs and bridges to prevent deformation and allow easy removal after printing.

Q: What density can be expected with optimized M2 3D printed parts?

A: Density above 99% is achievable for M2 using ideal parameters tailored specifically for this alloy.

Q: What defects can occur when printing M2 powder?

A: Potential defects are cracking, distortion, porosity, incomplete fusion, and surface roughness. Most can be prevented through optimized parameters.

Q: Is HIP required for all M2 AM tooling components?

A: While highly recommended, HIP may not be absolutely necessary for non-critical tooling applications. Heat treatment alone may suffice.

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