Crystals, Vol. 14, Pages 665: Advancements and Perspectives in Additive Manufacturing of Tungsten Alloys and Composites: Challenges and Solutions

Crystals, Vol. 14, Pages 665: Advancements and Perspectives in Additive Manufacturing of Tungsten Alloys and Composites: Challenges and Solutions

Crystals doi: 10.3390/cryst14070665

Authors: Mehrdad Zarinejad Yunxiang Tong Mojtaba Salehi Chengfa Mu Nian Wang Yonglong Xu Sajjad Rimaz Lintao Tian Kai Xiang Kuah Xiaotong Chen

This review explores additive manufacturing (AM) for refractory tungsten (W) and its alloys, highlighting the primary challenges and determining factors in the AM of pure W, W alloys and composites. The challenges mainly arise from W’s high melting point, low laser absorptivity, high thermal conductivity, high melt viscosity, high oxygen affinity, high ductile-to-brittle transition temperature, and inherent embrittlement, which lead to defects and anomalies in AM-produced parts. This review focuses on both processes and alloying strategies to address the issues related to densification, micro-cracking, and the resultant properties in W-based components. Cracking in additively manufactured W remains a persistent issue due to thermal stress, embrittlement, and oxide formation. Powder characteristics, process parameters, and thermal management strategies are crucial for W densification. Throughout the review, existing knowledge and insights are organized into comprehensive tables, serving as valuable resources for researchers delving deeper into this topic. Future research in W-AM should focus on understanding the interaction between AM process parameters and microstructural and material design. Advances in atomic-level understanding, thermodynamic modeling, and data analytics have the potential to significantly enhance the precision, sustainability, and applicability of W-AM.