In this work, a holistic approach for the fabrication of dense Ti6Al4V parts via material extrusion methods (MEX), such as fused filament fabrication (FFF) or fused feedstock deposition (FFD), will be presented. With respect to the requirements of the printing process, a comprehensive investigation of the feedstock development will be described. This covers mainly the amount ratio variation of the main binder components LDPE (low-density polyethylene), HDPE (high-density polyethylene), and wax, characterized by shear and oscillation rheology. Solid content of 60 vol% allowed the 3D printing of even more complex small parts in a reproducible manner. In some cases, the pellet-based FFD seems to be superior to the established FFF. After sintering, a density of 96.6% of theory could be achieved, an additional hot isostatic pressing delivered density values better than 99% of theory. The requirements (mechanical properties, carbon, and oxygen content) for the usage of medical implants (following ASTM F2885-17) were partially fulfilled or shortly missed.
Here we elucidate the mechanisms of plastic deformation and fracture of tungsten laminated composites. Our results suggest that the mechanical response of the laminates is governed by the plastic deformation of the tungsten plies. In most cases, the impact of the interlayer is of secondary importance. Severely cold-rolled ultrafine-grained tungsten foils possess exceptional properties in terms of brittle-to-ductile transition (BDT), toughness, and tensile ductility. The motivation for investigating laminated composites is to determine whether a bulk material can be made that retains the ductility of the thin tungsten foils. In this paper we analyse W-AgCu, W-Cu, W-V, and W-Pd laminates in their as-produced and annealed conditions (e.g. 10, 100 and 1000 h at 1000 °C (1273 K) in vacuum). The analyses comprise (i) the mechanical characterisation by means of three-point bending (damage tolerance), Charpy impact (BDT), and tensile tests (total elongation to fracture) as well as (ii) the in-depth analyses of the microstructure by means of scanning electron microscopy (SEM), transmission electron microscopy (TEM), and Auger electron spectroscopy (AES). W-Cu laminates (60 vol% W) show 15.5% total elongation to fracture in a tensile test at room temperature. Furthermore, the BDT of tungsten laminated composites occurs at a temperature that is several hundreds of Kelvin lower than the BDT temperature of the pure tungsten bulk counterparts. Finally, we present the successful fabrication of a 1000 mm long W-Cu laminated pipe and show its high heat flux performance. Fabrication studies of high heat flux components made of tungsten laminates, in which the laminates are used either as heat spreaders or structural pipes, are presented
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