Optimization of parameters for SLS of WC-Co

Purpose - WC-Co is a well-known material for conventional tooling but is not yet commercially available for additive manufacturing. Processing it by selective laser sintering (SLS) will pave the way for its commercialization and adoption. Design/methodology/approach - It is intended to optimize process parameters (laser power, hatch spacing, scan speed) by fabricating a bigger part (minimum size of 10 mm diameter and 5 mm height). Microstructural analysis, EDX and hardness testing is used to study effects of process parameters. Optimized parameter is ascertained after fabricating 49 samples in preliminary experiment, 27 samples in pre-final experiment and 9 samples in final experiment. Findings - Higher laser power gives rise to cracks and depletion of cobalt while higher scan speed increases porosity. Higher hatch spacing is responsible for delamination and displacement of parts. Optimized parameters are 270 W laser power, 500 mm/s scan speed, 0.04 mm layer thickness, 0.04 mm hatch spacing (resulting in energy density of 216 J/mm(3)) and 200 degrees C powder bed temperature. A part comprising of small hole of 2 mm diameter, thin cylindrical pin of 0.5 mm diameter and thin wall of 2 mm width bent up to 30 degrees angle to the base plate is fabricated. In order to calculate laser energy density, a new equation is introduced which takes into account both beam diameter and hatch spacing unlike old equation does. In order to calculate laser energy density, a new equation is formulated which takes into account both beam diameter and hatch spacing unlike old equation does. WC was not completely melted as intended giving rise to partial melting-type binding mechanism. This justified the name SLS for process in place of SLM (Selective Laser Melting). Research limitations/implications - Using all possible combination of parameters plus heating the part bed to maximum shows limitation of state-of-the-art commercial powder bed fusion machine for shaping hardmetal consisting of high amount of WC (83 wt. per cent). Practical implications - The research shows that microfeatures could be fabricated using WC-Co which will herald renewed interest in investigating hardmetals using SLS for manufacturing complex hard tools, molds and wear-resistance parts. Originality/value - This is the first time micro features are successfully fabricated using WC-Co without post-processing (infiltration, machining) and without the help of additional binding material (such as Cu, Ni, Fe).