Effects of processing parameters on rapid manufacturing 90W-7Ni-3Fe parts via selective laser melting

90W-7Ni-3Fe parts were fabricated via selective laser melting. The influences of processing parameters on the densification and microstructure were highlighted in this work. The compositions and microstructures of as produced alloys were investigated through X-ray diffraction, energy dispersive X-ray spectroscopy and SEM respectively. It is found that the phase structures are not evidently influenced by processing parameters. The density, surface characteristic and microstructure of final parts are dependent on processing parameters. Decreasing the scan speed is able to eliminate balling effect, diminish surface roughness, induce more melted W particles and yield better densification. Narrowing the scan interval is capable of creating a better bonding condition between scan tracks, obtaining a lower surface roughness and improved density. Decreasing the powder layer thickness is favourable for the layers bonding, leading to a higher densification.