Selective laser melting (SLM) additive manufacturing (AM) of hard-to-process W-based parts with the addition of 2.5 wt.% TiC was performed using a new metallurgical processing mechanism with the complete melting of the high-melting-point powder. The influence of SLM processing parameters, especially laser scan speed and attendant laser fluence (LF), on densification behavior, microstructural development, and hardness/wear performance of SLM-processed W-based alloy parts was disclosed. The densification response of SLM-processed W-based parts decreased both at a low LF of 10.7 J/mm2, caused by the limited SLM working temperature and wetting characteristics of the melt, and at an excessively high LF of 64 J/mm2, caused by the significant melt instability and resultant balling effect and microcracks formation. The laser-induced complete melting/solidification mechanism contributed to the solid solution alloying of Ti and C in W matrix and the development of unique microstructures of SLM-processed W-based alloy parts. As the applied LF increased by lowering laser scan speed, the morphologies of W-based crystals in SLM-processed alloy parts experienced a successive change from the cellular crystal to the cellular dendritic crystal and, finally, to the equiaxed dendritic crystal, due to an elevated constitutional undercooling and a decreased thermal undercooling. The optimally prepared W-based alloy parts by SLM had a nearly full densification rate of 97.8% theoretical density (TD), a considerably high microhardness of 809.9 HV0.3, and a superior wear/tribological performance with a decreased coefficient of friction (COF) of 0.41 and a low wear rate of 5.73 × 10−7 m3/(N m), due to the combined effects of the sufficiently high densification and novel crystal microstructures of SLM-processed W-based alloy parts.
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August 2016
Research-Article
Selective Laser Melting Additive Manufacturing of Hard-to-Process Tungsten-Based Alloy Parts With Novel Crystalline Growth Morphology and Enhanced Performance
Dongdong Gu,
Dongdong Gu
College of Materials Science and Technology,
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Institute of Additive Manufacturing (3D Printing),
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
e-mail: dongdonggu@nuaa.edu.cn
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
e-mail: dongdonggu@nuaa.edu.cn
Search for other works by this author on:
Donghua Dai,
Donghua Dai
College of Materials Science and Technology,
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Institute of Additive Manufacturing (3D Printing),
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
Search for other works by this author on:
Wenhua Chen,
Wenhua Chen
College of Materials Science and Technology,
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Institute of Additive Manufacturing (3D Printing),
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
Search for other works by this author on:
Hongyu Chen
Hongyu Chen
College of Materials Science and Technology,
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Institute of Additive Manufacturing (3D Printing),
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
Search for other works by this author on:
Dongdong Gu
College of Materials Science and Technology,
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Institute of Additive Manufacturing (3D Printing),
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
e-mail: dongdonggu@nuaa.edu.cn
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
e-mail: dongdonggu@nuaa.edu.cn
Donghua Dai
College of Materials Science and Technology,
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Institute of Additive Manufacturing (3D Printing),
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
Wenhua Chen
College of Materials Science and Technology,
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Institute of Additive Manufacturing (3D Printing),
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
Hongyu Chen
College of Materials Science and Technology,
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China;
Institute of Additive Manufacturing (3D Printing),
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
Nanjing University of Aeronautics and
Astronautics (NUAA),
Yudao Street 29,
Nanjing 210016, China
1Corresponding author.
Manuscript received June 22, 2015; final manuscript received November 23, 2015; published online March 28, 2016. Assoc. Editor: Z. J. Pei.
J. Manuf. Sci. Eng. Aug 2016, 138(8): 081003 (11 pages)
Published Online: March 28, 2016
Article history
Received:
June 22, 2015
Revised:
November 23, 2015
Citation
Gu, D., Dai, D., Chen, W., and Chen, H. (March 28, 2016). "Selective Laser Melting Additive Manufacturing of Hard-to-Process Tungsten-Based Alloy Parts With Novel Crystalline Growth Morphology and Enhanced Performance." ASME. J. Manuf. Sci. Eng. August 2016; 138(8): 081003. https://doi.org/10.1115/1.4032192
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