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Tertuliano OA, DePond PJ, Lee AC, Hong J, Doan D, Capaldi L, Brongersma M, Gu XW, Matthews MJ, Cai W, Lew AJ. High absorptivity nanotextured powders for additive manufacturing. SCIENCE ADVANCES 2024; 10:eadp0003. [PMID: 39231234 PMCID: PMC11373603 DOI: 10.1126/sciadv.adp0003] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Received: 03/01/2024] [Accepted: 07/29/2024] [Indexed: 09/06/2024]
Abstract
The widespread application of metal additive manufacturing (AM) is limited by the ability to control the complex interactions between the energy source and the feedstock material. Here, we develop a generalizable process to introduce nanoscale grooves to the surface of metal powders which increases the powder absorptivity by up to 70% during laser powder bed fusion. Absorptivity enhancements in copper, copper-silver, and tungsten enable energy-efficient manufacturing, with printing of pure copper at relative densities up to 92% using laser energy densities as low as 83 joules per cubic millimeter. Simulations show that the enhanced powder absorptivity results from plasmon-enabled light concentration in nanoscale grooves combined with multiple scattering events. The approach taken here demonstrates a general method to enhance the absorptivity and printability of reflective and refractory metal powders by changing the surface morphology of the feedstock without altering its composition.
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Affiliation(s)
- Ottman A Tertuliano
- Mechanical Engineering and Applied Mechanics, University of Pennsylvania, 220 S. 33rd St., Philadelphia, PA 19104, USA
- Mechanical Engineering, Stanford University, 452 Escondido Mall, Stanford, CA 94305, USA
| | - Philip J DePond
- Mechanical Engineering, Stanford University, 452 Escondido Mall, Stanford, CA 94305, USA
- Materials Science Division, Lawrence Livermore National Laboratory, 7000 East Ave, Livermore, CA 94550, USA
| | - Andrew C Lee
- Materials Science and Engineering, Stanford University, 496 Lomita Mall Suite 102, Stanford, CA 94305, USA
| | - Jiho Hong
- Materials Science and Engineering, Stanford University, 496 Lomita Mall Suite 102, Stanford, CA 94305, USA
| | - David Doan
- Mechanical Engineering, Stanford University, 452 Escondido Mall, Stanford, CA 94305, USA
| | - Luc Capaldi
- Mechanical Engineering and Applied Mechanics, University of Pennsylvania, 220 S. 33rd St., Philadelphia, PA 19104, USA
| | - Mark Brongersma
- Materials Science and Engineering, Stanford University, 496 Lomita Mall Suite 102, Stanford, CA 94305, USA
| | - X Wendy Gu
- Mechanical Engineering, Stanford University, 452 Escondido Mall, Stanford, CA 94305, USA
| | - Manyalibo J Matthews
- Materials Science Division, Lawrence Livermore National Laboratory, 7000 East Ave, Livermore, CA 94550, USA
| | - Wei Cai
- Mechanical Engineering, Stanford University, 452 Escondido Mall, Stanford, CA 94305, USA
| | - Adrian J Lew
- Mechanical Engineering, Stanford University, 452 Escondido Mall, Stanford, CA 94305, USA
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Howard L, Parker GD, Yu XY. Progress and Challenges of Additive Manufacturing of Tungsten and Alloys as Plasma-Facing Materials. MATERIALS (BASEL, SWITZERLAND) 2024; 17:2104. [PMID: 38730911 PMCID: PMC11084790 DOI: 10.3390/ma17092104] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 03/30/2024] [Revised: 04/25/2024] [Accepted: 04/25/2024] [Indexed: 05/13/2024]
Abstract
Tungsten (W) and W alloys are considered as primary candidates for plasma-facing components (PFCs) that must perform in severe environments in terms of temperature, neutron fluxes, plasma effects, and irradiation bombardment. These materials are notoriously difficult to produce using additive manufacturing (AM) methods due to issues inherent to these techniques. The progress on applying AM techniques to W-based PFC applications is reviewed and the technical issues in selected manufacturing methods are discussed in this review. Specifically, we focus on the recent development and applications of laser powder bed fusion (LPBF), electron beam melting (EBM), and direct energy deposition (DED) in W materials due to their abilities to preserve the properties of W as potential PFCs. Additionally, the existing literature on irradiation effects on W and W alloys is surveyed, with possible solutions to those issues therein addressed. Finally, the gaps in possible future research on additively manufactured W are identified and outlined.
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Affiliation(s)
- Logan Howard
- Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN 37830, USA
- The Bredesen Center, 310 Ferris Hall 1508 Middle Dr, Knoxville, TN 37996, USA
| | - Gabriel D. Parker
- Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN 37830, USA
| | - Xiao-Ying Yu
- Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN 37830, USA
- The Bredesen Center, 310 Ferris Hall 1508 Middle Dr, Knoxville, TN 37996, USA
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Xu L, Wang L, Chen H, Wang X, Chen F, Lyu B, Hang W, Zhao W, Yuan J. Effects of pH Values and H2O2 Concentrations on the Chemical Enhanced Shear Dilatancy Polishing of Tungsten. MICROMACHINES 2022; 13:mi13050762. [PMID: 35630229 PMCID: PMC9146294 DOI: 10.3390/mi13050762] [Citation(s) in RCA: 5] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 04/15/2022] [Revised: 05/05/2022] [Accepted: 05/10/2022] [Indexed: 11/25/2022]
Abstract
In order to obtain tungsten with great surface qualities and high polishing efficiency, a novel method of chemical enhanced shear dilatancy polishing (C-SDP) was proposed. The effects of pH values and H2O2 concentrations on the polishing performance of tungsten C-SDP were studied. In addition, the corrosion behaviors of tungsten in solutions with different pH values and H2O2 concentrations were analyzed by electrochemical experiments, and the valence states of elements on the tungsten surface were analyzed by XPS. The results showed that both pH values and H2O2 concentrations had significant effects on tungsten C-SDP. With the pH values increasing from 7 to 12, the MRR increased from 6.69 µm/h to 13.67 µm/h. The optimal surface quality was obtained at pH = 9, the surface roughness (Ra) reached 2.35 nm, and the corresponding MRR was 9.71 µm/h. The MRR increased from 9.71 µm/h to 34.95 µm/h with the H2O2 concentrations increasing from 0 to 2 vol.%. When the concentration of H2O2 was 1 vol.%, the Ra of tungsten reached the lowest value, which was 1.87 nm, and the MRR was 26.46 µm/h. This reveals that C-SDP technology is a novel ultra-precision machining method that can achieve great surface qualities and polishing efficiency of tungsten.
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Affiliation(s)
- Liang Xu
- College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou 310023, China; (L.X.); (L.W.); (X.W.); (F.C.); (B.L.); (W.H.); (W.Z.); (J.Y.)
| | - Lin Wang
- College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou 310023, China; (L.X.); (L.W.); (X.W.); (F.C.); (B.L.); (W.H.); (W.Z.); (J.Y.)
| | - Hongyu Chen
- College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou 310023, China; (L.X.); (L.W.); (X.W.); (F.C.); (B.L.); (W.H.); (W.Z.); (J.Y.)
- Key Laboratory of Special Purpose Equipment and Advanced Processing Technology, Ministry of Education and Zhejiang Province, Zhejiang University of Technology, Hangzhou 310023, China
- Correspondence:
| | - Xu Wang
- College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou 310023, China; (L.X.); (L.W.); (X.W.); (F.C.); (B.L.); (W.H.); (W.Z.); (J.Y.)
- Key Laboratory of Special Purpose Equipment and Advanced Processing Technology, Ministry of Education and Zhejiang Province, Zhejiang University of Technology, Hangzhou 310023, China
| | - Fangyuan Chen
- College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou 310023, China; (L.X.); (L.W.); (X.W.); (F.C.); (B.L.); (W.H.); (W.Z.); (J.Y.)
| | - Binghai Lyu
- College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou 310023, China; (L.X.); (L.W.); (X.W.); (F.C.); (B.L.); (W.H.); (W.Z.); (J.Y.)
- Key Laboratory of Special Purpose Equipment and Advanced Processing Technology, Ministry of Education and Zhejiang Province, Zhejiang University of Technology, Hangzhou 310023, China
| | - Wei Hang
- College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou 310023, China; (L.X.); (L.W.); (X.W.); (F.C.); (B.L.); (W.H.); (W.Z.); (J.Y.)
- Key Laboratory of Special Purpose Equipment and Advanced Processing Technology, Ministry of Education and Zhejiang Province, Zhejiang University of Technology, Hangzhou 310023, China
| | - Wenhong Zhao
- College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou 310023, China; (L.X.); (L.W.); (X.W.); (F.C.); (B.L.); (W.H.); (W.Z.); (J.Y.)
- Key Laboratory of Special Purpose Equipment and Advanced Processing Technology, Ministry of Education and Zhejiang Province, Zhejiang University of Technology, Hangzhou 310023, China
| | - Julong Yuan
- College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou 310023, China; (L.X.); (L.W.); (X.W.); (F.C.); (B.L.); (W.H.); (W.Z.); (J.Y.)
- Key Laboratory of Special Purpose Equipment and Advanced Processing Technology, Ministry of Education and Zhejiang Province, Zhejiang University of Technology, Hangzhou 310023, China
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Advanced Processing and Machining of Tungsten and Its Alloys. JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING 2022. [DOI: 10.3390/jmmp6010015] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/10/2022]
Abstract
Tungsten is a refractory metal with the highest melting temperature and density of all metals in this group. These properties, together with the high thermal conductivity and strength, make tungsten the ideal material for high-temperature structural use in fusion energy and other applications. It is widely agreed that the manufacture of components with complex geometries is crucial for scaling and optimizing power plant designs. However, there are challenges associated with the large-scale processing and manufacturing of parts made from tungsten and its alloys which limit the production of these complex geometries. These challenges stem from the high ductile-to-brittle transition temperature (DBTT), as well as the strength and hardness of these parts. Processing methods, such as powder metallurgy and additive manufacturing, can generate near-net-shaped components. However, subtractive post-processing techniques are required to complement these methods. This paper provides an in-depth exploration and discussion of different processing and manufacturing methods for tungsten and identifies the challenges and gaps associated with each approach. It includes conventional and unconventional machining processes, as well as research on improving the ductility of tungsten using various methods, such as alloying, thermomechanical treatment, and grain structure refinement.
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Jeffs S, Lancaster R, Davies G, Hole W, Roberts B, Stapleton D, Thomas M, Todd I, Baxter G. Effect of Process Parameters and Build Orientation on Microstructure and Impact Energy of Electron Beam Powder Bed Fused Ti-6Al-4V. MATERIALS (BASEL, SWITZERLAND) 2021; 14:5376. [PMID: 34576597 PMCID: PMC8466331 DOI: 10.3390/ma14185376] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 08/09/2021] [Revised: 09/07/2021] [Accepted: 09/15/2021] [Indexed: 11/16/2022]
Abstract
To fully exploit the benefits of additive manufacturing (AM), an understanding of its processing, microstructural, and mechanical aspects, and their interdependent characteristics, is necessary. In certain instances, AM materials may be desired for applications where impact toughness is a key property, such as in gas turbine fan blades, where foreign or direct object damage may occur. In this research, the impact energy of a series of Ti-6Al-4V specimens produced via electron beam powder bed fusion (EBPBF) was established via Charpy impact testing. Specimens were produced with five different processing parameter sets, in both the vertical and horizontal build orientation, with microstructural characteristics of prior β grain area, prior β grain width, and α lath width determined in the build direction. The results reveal that horizontally oriented specimens have a lower impact energy compared to those built in the vertical orientation, due to the influence of epitaxial grain growth in the build direction. Relationships between process parameters, microstructural characteristics, and impact energy results were evaluated, with beam velocity displaying the strongest trend in terms of impact energy results, and normalised energy density exhibiting the most significant influence across all microstructural measurements.
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Affiliation(s)
- Spencer Jeffs
- Bay Campus, Institute of Structural Materials, Faculty of Science and Engineering, Swansea University, Swansea SA1 8EN, UK; (R.L.); (W.H.); (B.R.)
| | - Robert Lancaster
- Bay Campus, Institute of Structural Materials, Faculty of Science and Engineering, Swansea University, Swansea SA1 8EN, UK; (R.L.); (W.H.); (B.R.)
| | - Gareth Davies
- Rolls-Royce plc, P.O. Box 31, Derby DE24 8BJ, UK; (G.D.); (D.S.)
| | - William Hole
- Bay Campus, Institute of Structural Materials, Faculty of Science and Engineering, Swansea University, Swansea SA1 8EN, UK; (R.L.); (W.H.); (B.R.)
| | - Brenna Roberts
- Bay Campus, Institute of Structural Materials, Faculty of Science and Engineering, Swansea University, Swansea SA1 8EN, UK; (R.L.); (W.H.); (B.R.)
| | - David Stapleton
- Rolls-Royce plc, P.O. Box 31, Derby DE24 8BJ, UK; (G.D.); (D.S.)
| | - Meurig Thomas
- Department of Materials Science and Engineering, University of Sheffield, Sir Robert Hadfield Building, Mappin Street, Sheffield S1 3JD, UK; (M.T.); (I.T.); (G.B.)
| | - Iain Todd
- Department of Materials Science and Engineering, University of Sheffield, Sir Robert Hadfield Building, Mappin Street, Sheffield S1 3JD, UK; (M.T.); (I.T.); (G.B.)
| | - Gavin Baxter
- Department of Materials Science and Engineering, University of Sheffield, Sir Robert Hadfield Building, Mappin Street, Sheffield S1 3JD, UK; (M.T.); (I.T.); (G.B.)
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