Abstract
W–Ni–Cu alloy (90 wt% W, 7.5 wt% Ni, and 2.5 wt% Cu) parts were successfully fabricated via selective laser melting method. Phases, microstructure, compositions, and laser forming parameters of laser melted samples were investigated. It was found that the W–Ni–Cu powder system was based on the mechanism of liquid solidification. This process was realized through full melting of W, Ni, and Cu particles under high laser energy input. However, using relatively lower energy input, particle bonding was realized through liquid phase sintering with complete melting of Ni–Cu acting as binder and nonmelting of W acting as structure. Due to the Ni–Cu solid solution phase that appeared in a wide range from 1,084 to 1,455 °C, a coherent matrix interface can be observed after solidification. The microhardness of laser-fabricated specimens varied with different powder layer thicknesses, resulting from the laser-treated condition and ability of trapped air in the loose powder bed to escape. The metallurgical mechanisms were also addressed.
Similar content being viewed by others
References
Wu WH, Yang YQ, Huang YL (2007) Direct manufacturing of Cu-based alloy parts by selective laser melting. Chin Opt Lett 5:37
Zhang DQ, Cai QZ, Liu JH, Zhang L, Li RD (2010) Select laser melting of W–Ni–Fe powders: simulation and experimental study. Int J Adv Manuf Technol 51:649
Junwu S, Luo C, Pavan S, German RM (2005) Quantitative microstructure analysis of tungsten heavy alloys (W–Ni–Cu) during initial stage liquid phase sintering. Int J Refract Met Hard Mater 23:99
Simchi A (2006) Direct laser sintering of metal powders: mechanism, kinetics and microstructural features. Mater Sci Eng A-Struct Mater Prop Microstruct and Process 428:148
Delgado J, Ciurana J, Rodriguez CA (2012) Influence of process parameters on part quality and mechanical properties for DMLS and SLM with iron-based materials. Int J Adv Manuf Technol 60:601
Jhabvala J, Boillat E, Andre C, Glardon R (2012) An innovative method to build support structures with a pulsed laser in the selective laser melting process. Int J Adv Manuf Technol 59:137
Childs THC, Hauser C, Badrossamay M (2005) Selective laser sintering (melting) of stainless and tool steel powders: experiments and modelling. Proc IME B J Eng Manufact 219:339
Abe F, Osakada K, Shiomi M, Uematsu K, Matsumoto M (2001) The manufacturing of hard tools from metallic powders by selective laser melting. J Mater Process Technol 111:210
Li RD, Liu JH, Shi YS, Wang L, Jiang W (2012) Balling behavior of stainless steel and nickel powder during selective laser melting process. Int J Adv Manuf Technol 59:1025
Liu JH, Lu ZL, Shi YS, Xu WW, Zhang J (2010) Investigation into manufacturing injection mold via indirect selective laser sintering. Int J Adv Manuf Technol 48:155
Song B, Dong SJ, Liao HL, Coddet C (2012) Process parameter selection for selective laser melting of Ti6Al4V based on temperature distribution simulation and experimental sintering. Int J Adv Manuf Technol 61:967
Tolosa I, Garciandia F, Zubiri F, Zapirain F, Esnaola A (2010) Study of mechanical properties of AISI 316 stainless steel processed by “selective laser melting”, following different manufacturing strategies. Int J Adv Manuf Technol 51:639
Wang FD (2012) Mechanical property study on rapid additive layer manufacture Hastelloy® X alloy by selective laser melting technology. Int J Adv Manuf Technol 58:545
Gu DD, Shen YF (2009) Effects of processing parameters on consolidation and microstructure of W–Cu components by DMLS. J Alloys Compd 473:107
Li R, Shi Y, Liu J, Xie Z, Wang Z (2009) Selective laser melting W–10 wt.% Cu composite powders. Int J Adv Manuf Tech 48:597
Kumar S (2009) Sliding wear behavior of dedicated iron-based SLS materials. Int J Adv Manuf Technol 43:337
Huang F, Jiang Z, Liu X, Lian J, Chen L (2009) Microstructure and properties of thin wall by laser cladding forming. J Materials Process Technol 209(11):4970
Osakada K, Shiomi M (2006) Flexible manufacturing of metallic products by selective laser melting of powder. Int J Mach Tool Manuf 46:1188
Jeng JY, Peng SC, Chou CJ (2000) Metal rapid prototype fabrication using selective laser cladding technology. Int J Adv Manuf Technol 16:681
Deng QL, Xie AN, Ge ZJ, Song JL (2006) Experimental researches on rapid forming full compacted metal parts by selective laser melting. Adv Mater Manuf Sci Technol II 532–533:428
Triantafyllidis D, Li L, Stott F (2003) Mechanisms of porosity formation along the solid/liquid interface during laser melting of ceramics. Appl Surf Sci 208–209:458
Gu DD, Shen YF (2006) WC-Co particulate reinforcing Cu matrix composites produced by direct laser sintering. Mater Lett 60:3664
Gu DD, Shen YF (2006) Processing and microstructure of submicron WC-Co particulate reinforced Cu matrix composites prepared by direct laser sintering. Mater Sci Eng A-Struct Mater Prop Microstruct and Process 435:54
Baroody EM (1967) J Appl Phys 38:4893
Yuan ZF, Ke JJ, Li J (2006) Surface tension of metals and alloys, 1st edn. Science Press, Beijing
Agarwala M, Bourell D, Beaman J, Marcus H, Barlow J (1995) Direct selective laser sintering of metals. Rapid Prototyping Journal 1:26
Gu DD, Shen YF, Yang JL, Wang Y (2006) Effects of processing parameters on direct laser sintering of multicomponent Cu based metal powder. Mater Sci Technol 22:1449
Zhong M, Liu W, Ning G, Yang L, Chen Y (2004) Laser direct manufacturing of tungsten nickel collimation component. J Mater Process Technol 147:167
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Zhang, D., Cai, Q., Liu, J. et al. Microstructural evolvement and formation of selective laser melting W–Ni–Cu composite powder. Int J Adv Manuf Technol 67, 2233–2242 (2013). https://doi.org/10.1007/s00170-012-4644-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-012-4644-8