Additive Manufacturing of Cemented Tungsten Carbide with a Cobalt-Free Alloy Binder by Selective Laser Melting for High-Hardness Applications

Ku, Nicholas; Pittari, John J.; Kilczewski, Steven; Kudzal, Andelle

doi:10.1007/s11837-019-03366-2

Cited by 43 publications

(23 citation statements)

References 12 publications

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“…In SLM, the density of the sample increases as the energy density increases [73,109], like reported in other materials [135][136][137]. When the parameters are suitable, the relative density can reach more than 95% [70,73,114]. Density of high porosity SLM samples can be increased by HIP (hot isostatic pressing) sintering [114].…”

Section: Mechanical Propertiesmentioning

confidence: 71%

“…Samples prepared by SEBM usually have macroscopically visible pores that can be eliminated by sintering [41]. Porosity in SLM samples can also be eliminated by HIP (hot isostatic pressing) due to the rearrangement and diffusion of particles when the energy density is not too low to cause a large number of porosities [114].…”

Section: Fused Filament Fabricationmentioning

confidence: 99%

“…When the parameters are suitable, the relative density can reach more than 95% [70,73,114]. Density of high porosity SLM samples can be increased by HIP (hot isostatic pressing) sintering [114]. In addition, the use of irregular powders results in a decrease in sample density [65].…”

Section: Mechanical Propertiesmentioning

confidence: 99%

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Additive manufacturing of WC-Co hardmetals: a review

Yang

Zhang

Wang

et al. 2020

Int J Adv Manuf Technol

104

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WC-Co hardmetals are widely used in wear-resistant parts, cutting tools, molds, and mining parts, owing to the combination of high hardness and high toughness. WC-Co hardmetal parts are usually produced by casting and powder metallurgy, which cannot manufacture parts with complex geometries and often require post-processing such as machining. Additive manufacturing (AM) technologies are able to fabricate parts with high geometric complexity and reduce post-processing. Therefore, additive manufacturing of WC-Co hardmetals has been widely studied in recent years. In this article, the current status of additive manufacturing of WC-Co hardmetals is reviewed. The advantages and disadvantages of different AM processes used for producing WC-Co parts, including selective laser melting (SLM), selective electron beam melting (SEBM), binder jet additive manufacturing (BJAM), 3D gel-printing (3DGP), and fused filament fabrication (FFF) are discussed. The studies on microstructures, defects, and mechanical properties of WC-Co parts manufactured by different AM processes are reviewed. Finally, the remaining challenges in additive manufacturing of WC-Co hardmetals are pointed out and suggestions on future research are discussed.

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Section: Mechanical Propertiesmentioning

confidence: 71%

Section: Fused Filament Fabricationmentioning

confidence: 99%

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Additive manufacturing of WC-Co hardmetals: a review

Yang

Zhang

Wang

et al. 2020

Int J Adv Manuf Technol

104

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“…Currently, methods such as inductively coupled RF plasma spheroidization and water atomization can be used to form spherical particles. However, most of the methods are not able to produce spherical tungsten carbide powders due to its high melting point (2870°C) (Ku et al, 2019). The RF plasma method is an exception.…”

Section: Radio Frequency (Rf) Plasma Spheroidisationmentioning

confidence: 99%

Evaluation of spheroidized tungsten carbide powder produced by induction plasma melting

Dire

Bissett

Delport

et al. 2021

J. S. Afr. Inst. Min. Metall.

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SYNOPSIS Tungsten carbide is a fine grey powder. It can be formed into shapes by compacting with the addition of a binder. Spherical particles are generally preferred in additive manufacturing as they pack together more efficiently than non-spherical particles, promoting a uniform powder bed density, better flowability, and elimination of internal cavities and fractures, resulting in a better quality of final product. The particle shape of powders can be transformed into spherical through the process of spheroidization. However, due to its high melting point, tungsten carbide could be difficult to spheroidize. Tungsten carbide was spheroidized using an inductively coupled radio frequency plasma at various plate powers between 9 and 15 kW. The influence of additional H2 in the sheath gas on the chemical composition of the tungsten carbide product was also investigated by means of XRD, which indicated that WC is converted to W2C at higher H2 concentrations. Optical analysis of SEM micrographs indicated that the spheroidization ratio increased with increased plasma energy. Keywords: spheroidization, induction plasma melting, tungsten carbide.

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“…2(a). As the hardness of ceramics generally follows a Hall-Petch-like relationship 14 , it is important to use finer ceramic particles in order to obtain finer microstructure with higher hardness. However, there is a few hurdles in controlling particles with nano to submicron scale in the LDED system.…”

Section: Multi-beam Laser Directed Energy Deposition (Multi-beam Ldedmentioning

confidence: 99%

Effects of Laser-Beam Defocus on Microstructural Features of Compositionally Graded WC/Co-Alloy Composites Additively Manufactured by Multi-Beam Laser Directed Energy Deposition

Kunimine

Miyazaki

Yamashita

et al. 2020

Sci Rep

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Establishing processing routes for obtaining metal-matrix composites (MMCs) with uniformly-dispersed reinforcements is one of the main subjects in additively manufactured composite materials to achieve designed microstructures and mechanical properties. Here we report on the microstructural features of compositionally graded WC/Co-alloy composites additively manufactured by multi-beam laser directed energy deposition (multi-beam LDED). For tailoring microstructures of compositionally graded WC/ Co-alloy composites with uniformly-dispersed reinforcements, the combinational method: the laserbeam defocus function in the multi-beam LDED system and granulated powder was attempted. By laser defocusing in the multi-beam LDED system, composites with uniformly-dispersed WC particles in Co alloy matrix was successfully obtained due to melting of Co bond in WC-12 wt.%Co granulated particles. It was found that the laser defocusing of multi-beam lasers affects temperature increase of flying powder during the laser focusing area, resulting in change of processing mode from melt-pool mode to thermal spray mode. The preferable property gradients in the WC/Co-alloy composites could be obtained by controlling the feeding rate of the powders and laser-beam defocus. These experimental results demonstrated the effectiveness of the laser-beam-defocus function in the multi-beam LDED system as a key factor for tailoring microstructures of additively-manufactured functionally graded MMCs with uniformly-dispersed reinforcements.

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Additive Manufacturing of Cemented Tungsten Carbide with a Cobalt-Free Alloy Binder by Selective Laser Melting for High-Hardness Applications

Cited by 43 publications

References 12 publications

Additive manufacturing of WC-Co hardmetals: a review

Additive manufacturing of WC-Co hardmetals: a review

Evaluation of spheroidized tungsten carbide powder produced by induction plasma melting

Effects of Laser-Beam Defocus on Microstructural Features of Compositionally Graded WC/Co-Alloy Composites Additively Manufactured by Multi-Beam Laser Directed Energy Deposition

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