Selective laser melting (SLM) additive manufacturing of pure tungsten encounters nearly all intractable difficulties of SLM metals fields due to its intrinsic properties. The key factors, including powder characteristics, layer thickness, and laser parameters of SLM high density tungsten are elucidated and discussed in detail. The main parameters were designed from theoretical calculations prior to the SLM process and experimentally optimized. Pure tungsten products with a density of 19.01 g/cm3 (98.50% theoretical density) were produced using SLM with the optimized processing parameters. A high density microstructure is formed without significant balling or macrocracks. The formation mechanisms for pores and the densification behaviors are systematically elucidated. Electron backscattered diffraction analysis confirms that the columnar grains stretch across several layers and parallel to the maximum temperature gradient, which can ensure good bonding between the layers. The mechanical properties of the SLM-produced tungsten are comparable to that produced by the conventional fabrication methods, with hardness values exceeding 460 HV0.05 and an ultimate compressive strength of about 1 GPa. This finding offers new potential applications of refractory metals in additive manufacturing.

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Despite the popularity of a number of techniques of thermochemical diffusion for titanium, in many cases the surface engineering processes used may not be economically viable options for industry. This work focuses on the application of Powder Immersion Reaction Assisted Coating (PIRAC), a relatively inexpensive nitriding treatment that is capable of providing a remarkable improvement in the surface characteristics of titanium alloys. The aim of this work was to determine whether PIRAC could be successfully applied to Ti-6Al-4V and the high-performance near-titanium alloy Timetal 834. In order to study the response of these materials to PIRAC nitriding, techniques such as X-ray diffraction, micro-indentation hardness, surface profilometry, optical and electron microscopy, nano-scratch adhesion testing and ball-on-plate reciprocatingsliding wear testing were employed. These techniques highlighted the markedly different response between the two alloys to the PIRAC treatment; namely, that Ti-6Al-4V forms a thick compound layer, while at the same processing temperature and time Timetal834 does not form any appreciable Ti 2 N phase instead forming a nitrogen-diffusion case with a thin TiN compound layer at the surface. This inherent difference in nitridability influences the metallurgical response of each alloy. Despite this, the surfaces of both alloys were still hardened considerably and their tribological performance in dry sliding conditions improved compared to the untreated alloys.

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