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<p>Laser-based powder bed fusion (PBF-LB/M) holds potential for creating complex geometries in tungsten carbide–cobalt (WC–Co) composites, valued for their hardness and thermal resilience in cutting tools. Traditional WC–Co fabrication via liquid-phase sintering provides high density and strength, but limits design flexibility. In contrast, PBF-LB/M allows intricate designs like optimized cooling channels. However, challenges arise due to localized high-energy laser inputs, risking binder vaporization and formation of undesired phases that cause embrittlement and WC grain growth. This study investigates WC–Ni 83/17 as an alternative binder to improve PBF-LB/M results. Samples were produced and evaluated using two methods: a single-stage PBF-LB/M process and a two-stage process combining low-energy PBF-LB/M, resulting in a less damaged but porous microstructure, followed by hot isostatic pressing (HIP). This method produced dense WC–Ni samples with 30% higher average transverse rupture strength, up to 2300 N/mm<sup>2</sup>, attributed to their finer grain structure compared to WC–Co 83/17 processed by PBF-LB/M. The downstream sinter-HIP caused anisotropic but reproducible shrinkage due to the PBF-LB/M build direction. Determining the <i>x</i>-, <i>y</i>-, and <i>z</i>-shrinkage allowed tool demonstrators to be successfully compensated for shrinkage, manufactured using the described two-stage process, and tested in machining applications. PBF-LB/M-produced tungsten carbide claws demonstrated significantly less wear than the PBF-LB/M tool steel claws after 4500 cutting operations. The results indicate that WC–Ni with controlled PBF-LB/M and sinter-HIP processing offers a promising alternative to high-strength and high-hardness steels for abrasion-exposed components and parts, combining hardness and toughness with design flexibility. </p>

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Laser-based powder bed fusion of WC–Ni for additive manufacturing of wear-resistant tool components

  • 期刊论文

  • 发表日期：

    2025年4月28日

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  • Leon Engelhardt,
  • Tobias Schwanekamp,
  • Martin Reuber

摘要

Laser-based powder bed fusion (PBF-LB/M) holds potential for creating complex geometries in tungsten carbide–cobalt (WC–Co) composites, valued for their hardness and thermal resilience in cutting tools. Traditional WC–Co fabrication via liquid-phase sintering provides high density and strength, but limits design flexibility. In contrast, PBF-LB/M allows intricate designs like optimized cooling channels. However, challenges arise due to localized high-energy laser inputs, risking binder vaporization and formation of undesired phases that cause embrittlement and WC grain growth. This study investigates WC–Ni 83/17 as an alternative binder to improve PBF-LB/M results. Samples were produced and evaluated using two methods: a single-stage PBF-LB/M process and a two-stage process combining low-energy PBF-LB/M, resulting in a less damaged but porous microstructure, followed by hot isostatic pressing (HIP). This method produced dense WC–Ni samples with 30% higher average transverse rupture strength, up to 2300 N/mm2, attributed to their finer grain structure compared to WC–Co 83/17 processed by PBF-LB/M. The downstream sinter-HIP caused anisotropic but reproducible shrinkage due to the PBF-LB/M build direction. Determining the x-, y-, and z-shrinkage allowed tool demonstrators to be successfully compensated for shrinkage, manufactured using the described two-stage process, and tested in machining applications. PBF-LB/M-produced tungsten carbide claws demonstrated significantly less wear than the PBF-LB/M tool steel claws after 4500 cutting operations. The results indicate that WC–Ni with controlled PBF-LB/M and sinter-HIP processing offers a promising alternative to high-strength and high-hardness steels for abrasion-exposed components and parts, combining hardness and toughness with design flexibility.