Additive manufacturing of high density pure tungsten by electron beam melting. (September 2021) - Dorow-Gerspach, D.
Graphical abstract: Highlights: Nearly-crack free bulk material with theoretical density above 99% was produced. Transition regime between sintering, partial, and complete melting was identified. Performance under ITER-like stationary and transient heat loads as recrystallized W. A columnar grain structure with a pronounced in-plane texture could be built. Near net-shape manufacturing of ITER-type monoblocks was demonstrated. Abstract: Tungsten is an outstanding material and due to its properties like highest melting point and tensile strength of all natural metals and its high thermal conductivity it is a prime candidate for being used in very harsh environments and for challenging applications like X-ray tubes or as plasma facing material (PFM) in fusion reactors. Unfortunately, high brittle to ductile transition temperature and hardness represent a great challenge for classic manufacturing processes. Additive manufacturing (AM) of tungsten could overcome these limitations and resulting design restrictions. However, AM of tungsten also poses challenges in particular related to the production of material of high density and mechanical stability. Using a selective electron beam melting and a base temperature of 1000 °C of the powder, we were able to produce tungsten with a theoretical density of 99 % without the need of any post-treatment like a second melting step or a redensification by e.g. hot isostatic pressing (HIP). The surface morphology, microstructure, hardness, thermal conductivity and stability against severe transient heat loads were investigated with respect to the relevant building parameters and compared with recrystallized standard W. Besides simple test geometries also more sophisticated ones like monoblocks were successfully realized illustrating the potential of AM for fusion.