Crack-Free Tungsten Fabricated via Laser Powder Bed Fusion Additive Manufacturing

Tejas Ramakrishnan; Amit Kumar; Tumulu S. Kumar; Sunyong Kwon; Jose A. Muniz-Lerma; Raynald Gauvin; Mathieu Brochu

doi:10.1002/adfm.202309304

Crack-Free Tungsten Fabricated via Laser Powder Bed Fusion Additive Manufacturing

Tejas Ramakrishnan, Amit Kumar, Tumulu S. Kumar, Sunyong Kwon, Jose A. Muniz-Lerma, Raynald Gauvin, Mathieu Brochu

Multiscale Modeling & Materials by Desig

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20 Scopus citations

Abstract

Additive manufacturing of tungsten (W) is challenging due to its high melting point, high thermal conductivity, oxidation tendency, and brittleness from grain boundary (GB) oxides. In this study, the processing of W through laser powder bed fusion is investigated. Parts are fabricated under argon (Ar) and nitrogen (N₂) atmospheres using the same processing parameters. The part produced in Ar has cracks with oxide precipitates decorating the fractured GBs. On the other hand, crack-free W samples are produced under N₂ atmosphere without any additional process modification. In both cases, the oxygen (O) content in the LPBF samples is similar to the starting powder. Interestingly, the analysis of the samples fabricated in nitrogen suggests that nitrogen is retained beyond the equilibrium solid solubility limit, while high-resolution electron micrographs of fractured surfaces reveal reduced levels of oxides at GBs. Increased hardness for samples processed under N₂ atmosphere is observed. Density Functional Theory (DFT) calculations performed to study the influence of interstitial nitrogen on oxygen diffusion in W indicated a hindrance to O diffusion from the presence of dissolved N.

Original language	English
Article number	2309304
Journal	Advanced Functional Materials
Volume	34
Issue number	12
DOIs	https://doi.org/10.1002/adfm.202309304
State	Published - Mar 18 2024

Funding

The authors would like to thank the research support provided by the Natural Sciences and Engineering Research Council (NSERC) of Canada (NSERC Project Number: NSERC RGPIN\u20102019\u201005296). The authors would like to thank Nicolas Brodusch for the assistance provided in high magnification electron microscopy. The authors would also like to acknowledge the McGill Engineering Doctoral Award (MEDA) granted to Tejas Ramakrishnan.

Keywords

DFT calculations
grain boundary engineering
laser powder bed fusion
refractory metal
tungsten

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title = "Crack-Free Tungsten Fabricated via Laser Powder Bed Fusion Additive Manufacturing",

abstract = "Additive manufacturing of tungsten (W) is challenging due to its high melting point, high thermal conductivity, oxidation tendency, and brittleness from grain boundary (GB) oxides. In this study, the processing of W through laser powder bed fusion is investigated. Parts are fabricated under argon (Ar) and nitrogen (N2) atmospheres using the same processing parameters. The part produced in Ar has cracks with oxide precipitates decorating the fractured GBs. On the other hand, crack-free W samples are produced under N2 atmosphere without any additional process modification. In both cases, the oxygen (O) content in the LPBF samples is similar to the starting powder. Interestingly, the analysis of the samples fabricated in nitrogen suggests that nitrogen is retained beyond the equilibrium solid solubility limit, while high-resolution electron micrographs of fractured surfaces reveal reduced levels of oxides at GBs. Increased hardness for samples processed under N2 atmosphere is observed. Density Functional Theory (DFT) calculations performed to study the influence of interstitial nitrogen on oxygen diffusion in W indicated a hindrance to O diffusion from the presence of dissolved N.",

keywords = "DFT calculations, grain boundary engineering, laser powder bed fusion, refractory metal, tungsten",

author = "Tejas Ramakrishnan and Amit Kumar and Kumar, \{Tumulu S.\} and Sunyong Kwon and Muniz-Lerma, \{Jose A.\} and Raynald Gauvin and Mathieu Brochu",

note = "Publisher Copyright: {\textcopyright} 2023 The Authors. Advanced Functional Materials published by Wiley-VCH GmbH.",

year = "2024",

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doi = "10.1002/adfm.202309304",

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T1 - Crack-Free Tungsten Fabricated via Laser Powder Bed Fusion Additive Manufacturing

AU - Ramakrishnan, Tejas

AU - Kumar, Amit

AU - Kumar, Tumulu S.

AU - Kwon, Sunyong

AU - Muniz-Lerma, Jose A.

AU - Gauvin, Raynald

AU - Brochu, Mathieu

PY - 2024/3/18

Y1 - 2024/3/18

N2 - Additive manufacturing of tungsten (W) is challenging due to its high melting point, high thermal conductivity, oxidation tendency, and brittleness from grain boundary (GB) oxides. In this study, the processing of W through laser powder bed fusion is investigated. Parts are fabricated under argon (Ar) and nitrogen (N2) atmospheres using the same processing parameters. The part produced in Ar has cracks with oxide precipitates decorating the fractured GBs. On the other hand, crack-free W samples are produced under N2 atmosphere without any additional process modification. In both cases, the oxygen (O) content in the LPBF samples is similar to the starting powder. Interestingly, the analysis of the samples fabricated in nitrogen suggests that nitrogen is retained beyond the equilibrium solid solubility limit, while high-resolution electron micrographs of fractured surfaces reveal reduced levels of oxides at GBs. Increased hardness for samples processed under N2 atmosphere is observed. Density Functional Theory (DFT) calculations performed to study the influence of interstitial nitrogen on oxygen diffusion in W indicated a hindrance to O diffusion from the presence of dissolved N.

AB - Additive manufacturing of tungsten (W) is challenging due to its high melting point, high thermal conductivity, oxidation tendency, and brittleness from grain boundary (GB) oxides. In this study, the processing of W through laser powder bed fusion is investigated. Parts are fabricated under argon (Ar) and nitrogen (N2) atmospheres using the same processing parameters. The part produced in Ar has cracks with oxide precipitates decorating the fractured GBs. On the other hand, crack-free W samples are produced under N2 atmosphere without any additional process modification. In both cases, the oxygen (O) content in the LPBF samples is similar to the starting powder. Interestingly, the analysis of the samples fabricated in nitrogen suggests that nitrogen is retained beyond the equilibrium solid solubility limit, while high-resolution electron micrographs of fractured surfaces reveal reduced levels of oxides at GBs. Increased hardness for samples processed under N2 atmosphere is observed. Density Functional Theory (DFT) calculations performed to study the influence of interstitial nitrogen on oxygen diffusion in W indicated a hindrance to O diffusion from the presence of dissolved N.

KW - DFT calculations

KW - grain boundary engineering

KW - laser powder bed fusion

KW - refractory metal

KW - tungsten

UR - https://www.scopus.com/pages/publications/85179370004

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DO - 10.1002/adfm.202309304

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AN - SCOPUS:85179370004

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JO - Advanced Functional Materials

JF - Advanced Functional Materials

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M1 - 2309304

ER -

Crack-Free Tungsten Fabricated via Laser Powder Bed Fusion Additive Manufacturing

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Keywords

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