Selective laser melting additive manufacturing of pure tungsten: Role of volumetric energy density on densification, microstructure and mechanical properties

Due to the intrinsic properties of tungsten, such as high melting point and high thermal conductivity, selective laser melting of pure W parts experiences many challenges. In this study, the effects of volumetric energy density on the densification behavior, microstructure evolution and mechanical performances of SLM-processed pure tungsten parts were investigated. A maximum density of 19.0 g/cm(3) (98.4% of the theoretical density) was obtained at the optimal energy density of 1000 J/mm(3) and its microstructure was free of pores and balling phenomenon. The formation mechanism of pores and cracks was systematically investigated. The microhardness and compressive strength of SLM-processed pure W parts reached 474 HV and 902 MPa, respectively, which were comparable to the samples produced by conventional manufacturing methods. The morphology of fracture demonstrated that the fracture mechanism of SLM-processed pure W parts was brittle fracture and intergranular fracture was the main fracture mode. Dry sliding wear tests showed that the wear mechanism changed with the energy density. For pure W parts processed by SLM at the optimal parameters, the adhesion of hardened tribolayers was formed. In this case, the reduced coefficient of friction (COF) of 0.45 and a low wear rate of 1.3 x 10(-5) mm(3).N-1.m(-1 )were obtained.