Processing of tungsten through electron beam melting

Ellis, Elizabeth A.; Sprayberry, Michael; Ledford, Christopher; Kirka, Michael M.; Rock, Chris; Horn, Timothy; Katoh, Yutai; Dehoff, Ryan R.

doi:10.1016/j.jnucmat.2021.153041

Cited by 40 publications

(34 citation statements)

References 31 publications

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“…High-relative-density (>99%) samples of pure Nb and Nb-1Zr were formed between VED = 175-300 J/mm 3 , especially when beam power exceeded 600 W. Nb-10W-1Zr-0.1C and Nb-20W-1Zr-0.1C were highly dense at 300 J/mm 3 but decreased sharply as VED approached 1500 J/mm 3 . VED of this magnitude is similar to that required for pure W, according to our EB-PBF and LPBF process maps [34]. The parameters meant to sufficiently melt the tungsten actually overmelted the Nb-1Zr matrix, leaving clusters of semi-melted W solidified in a defect-prone Nb-1Zr matrix.…”

Section: Processing Space and Parameter Effects On Microstructuresupporting

confidence: 74%

“…The limited quantity of powder (~5 kg of each composition) prohibited an extensive experimental process parameter search. Instead, limits were imposed on the processing space based on our recent work on W [34] and our internal, preliminary work on pure Nb. Theoretically, Nb and W process parameters should represent the extremes of the processing space for these three alloys.…”

Section: Sample Fabricationmentioning

confidence: 99%

“…A distinct advantage of the small build tank setup used in this study is heat distribution over a smaller volume, limiting heat transfer to surrounding components in the chamber which are stainless steel in most Arcam machines. This small build tank design has facilitated EB-PBF of other refractory materials including W [34], Mo+TiC [12], and C-103 [25].…”

Section: Sample Fabricationmentioning

confidence: 99%

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Electron Beam Melting of Niobium Alloys from Blended Powders

et al. 2021

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Niobium-based tungsten alloys are desirable for high-temperature structural applications yet are restricted in practice by limited room-temperature ductility and fabricability. Powder bed fusion additive manufacturing is one technology that could be leveraged to process alloys with limited ductility, without the need for pre-alloying. A custom electron beam powder bed fusion machine was used to demonstrate the processability of blended Nb-1Zr, Nb-10W-1Zr-0.1C, and Nb-20W-1Zr-0.1C powders, with resulting solid optical densities of 99+%. Ultimately, post-processing heat treatments were required to increase tungsten diffusion in niobium, as well as to attain satisfactory mechanical properties.

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Section: Processing Space and Parameter Effects On Microstructuresupporting

confidence: 74%

Section: Sample Fabricationmentioning

confidence: 99%

Section: Sample Fabricationmentioning

confidence: 99%

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Electron Beam Melting of Niobium Alloys from Blended Powders

et al. 2021

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“…[ 66 ] E‐PBF was shown to be able to print crack‐free parts in a vacuum environment and with substrate preheating temperatures well above the ductile‐to‐brittle transition temperatures (above 1100 °C). [ 67 ] There are different methods to colorize manufactured jewelry pieces. For instance, by anodization of titanium rings and creating an oxide layer (with a defined thickness), a range of colors can be obtained due to the light interference at the metal‐oxide‐air interface.…”

Section: Emerging Metals In Ammentioning

confidence: 99%

Emerging Functional Metals in Additive Manufacturing

Moghimian¹,

Poirié²,

Kroeger³

et al. 2023

Adv Eng Mater

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“…[6] For achieving more complex geometrical features and greater freedom of design, 3D printing techniques such as selective laser melting (SLM) and electron beam melting (EBM) have been reported for the manufacturing of tungsten and tungsten carbide components. [37][38][39][40] SLM was, for example, utilized to manufacture pure tungsten 3D multicollimators with a resolution of 460 μm. [7] However, the surface quality of SLM-manufactured parts is poor with surface roughness R a values ranging from 9 to 14 μm.…”

Section: Introductionmentioning

confidence: 99%

High‐Resolution Patterning of Organic–Inorganic Photoresins for Tungsten and Tungsten Carbide Microstructures

et al. 2023

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Tungsten is an important material for high‐temperature applications due to its high chemical and thermal stability. Its carbide, that is, tungsten carbide, is used in tool manufacturing because of its outstanding hardness and as a catalyst scaffold due to its morphology and large surface area. However, microstructuring, especially high‐resolution 3D microstructuring of both materials, is a complex and challenging process which suffers from slow speeds and requires expensive specialized equipment. Traditional subtractive machining methods, for example, milling, are often not feasible because of the hardness and brittleness of the materials. Commonly, tungsten and tungsten carbide are manufactured by powder metallurgy. However, these methods are very limited in the complexity and resolution of the produced components. Herein, tungsten ion‐containing organic–inorganic photoresins, which are patterned by two‐photon lithography (TPL) at micrometer resolution, are introduced. The printed structures are converted to tungsten or tungsten carbide by thermal debinding and reduction of the precursor or carbothermal reduction reaction, respectively. Using TPL, complex 3D tungsten and tungsten carbide structures are prepared with a resolution down to 2 and 7 μm, respectively. This new pathway of structuring tungsten and its carbide facilitates a broad range of applications from micromachining to metamaterials and catalysis.

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Processing of tungsten through electron beam melting

Cited by 40 publications

References 31 publications

Electron Beam Melting of Niobium Alloys from Blended Powders

Electron Beam Melting of Niobium Alloys from Blended Powders

Emerging Functional Metals in Additive Manufacturing

High‐Resolution Patterning of Organic–Inorganic Photoresins for Tungsten and Tungsten Carbide Microstructures

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