The role of nanocrystalline binder metallic coating into WC after additive manufacturing

Although ceramic particle-metal matrix materials (i.e., cermets) can offer superior performance, manufacturing these materials via conventional means is difficult compared to the manufacturing of metal alloys. This study leverages the laser powder bed fusion (LPBF) process to additively manufacture dense tungsten carbide (WC)-17 wt.% nickel (Ni) composite specimens using novel spherical, sintered-agglomerated composite powder. A range of processing parameters yielding high-density specimens was discovered using a sequential series of experiments comprised of single bead, multi-layer, and cylindrical builds. Cylinders with a relative density >99% were fabricated and characterized in terms of microstructure, chemical composition, and hardness. Scanning electron microscopy images show favorable wetting between the Ni binder and carbide particles without any phase segregation and laser processing increased the average carbide particle size. Energy dispersive X-ray and X-ray diffraction analyses detected traces of secondary products after laser processing.For samples processed at high energy densities, complex carbides and carbon agglomerate phases were detected. The maximum hardness of 60.38 Rockwell C is achieved in the printed samples. The successful builds in this study open the way for LPBF of dense WC-Ni parts with a large workable laser power-laser velocity processing window.

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“…Cavaleiro et al. conducted a study on surface‐modified WC particles to print a WC cermet reinforced with steel 27 …”

Section: Introductionmentioning

confidence: 99%

Process development for the laser powder bed fusion of WC‐Ni Cermets using sintered‐agglomerated powder

Jimenez

Reeja‐Jayan

Beuth

2022

Int J Applied Ceramic Tech

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“…In an effort to overcome processing challenges associated with SLM of cemented WC materials, creative solutions have been investigated. Cavaleiro et al 10 sputtered a coating of stainless steel onto the WC particles to promote better mixing of the powder and binder phases, but the resultant samples still had high residual porosity, due to the poor wetting of WC by steel. However, the coating of particles is generally an effective way to promote better absorption of laser energy by the binder phase, in turn leading to more effective fusion of the particles.…”

Section: Introductionmentioning

confidence: 99%

“…11 Previous work in SLM of cemented WC all utilized WC powder with particle sizes ranging from several microns to tens of microns. 6,8,10,11 The hardness of WC generally follows a Hall-Petch-like relationship, in which a finer grain size yields a higher hardness of the material. 12 Therefore, it is important to start with the finest particle size of WC in order to minimize the grain size and maximize the hardness of the final part.…”

Section: Introductionmentioning

confidence: 99%

Additive Manufacturing of Cemented Tungsten Carbide with a Cobalt-Free Alloy Binder by Selective Laser Melting for High-Hardness Applications

Pittari

Kilczewski

et al. 2019

JOM

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Cemented tungsten carbide (WC) is commonly used for wear-resistant applications, such as cutting tools and abrasives due to its extremely high hardness. This hardness leads to post-process machining of WC to be time-and cost-intensive. This study examined the feasibility of additive manufacturing of cemented WC to near-net-shape in an effort to reduce post-process machining. The binder phase in the manufactured samples is an iron-based alloy, which has a lower melting temperature than cobalt, the conventional binder in cemented WC. In this proof-of-concept study, cuboid specimens of WC with a low content of the iron-based alloy binder were printed; the effect of different processing conditions on the resultant density and microstructure of the material were investigated. Theoretical densities as high as 95% were achieved using this method. Artifacts indicative of the manufacturing process are present in the samples, and the challenges in removing the processing history from the final microstructure are discussed.

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“…The SLS process is being widely used in the manufacturing industries. The main advantage over other AM processes is its ability to produce parts in a wide range of materials and adapted to produce prototypes from metals that can be used with excellent precision and reliability for RT applications (King and Tansey, 2003;Cavaleiro et al, 2018;Danezan et al, 2018;Yan et al, 2016). Shirazi et al (2015), reported that Inkjet 3D-P and SLS are two flexible and effective AM technologies that are applicable to produce parts from powder metals.…”

Section: Introduction Of Rapid Toolingmentioning

confidence: 99%

The potential of metal epoxy composite (MEC) as hybrid mold inserts in rapid tooling application: a review

Hussin

Sharif

Rahim

et al. 2021

RPJ

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Purpose Rapid tooling (RT) integrated with additive manufacturing technologies have been implemented in various sectors of the RT industry in recent years with various kinds of prototype applications, especially in the development of new products. The purpose of this study is to analyze the current application trends of RT techniques in producing hybrid mold inserts. Design/methodology/approach The direct and indirect RT techniques discussed in this paper are aimed at developing a hybrid mold insert using metal epoxy composite (MEC) in increasing the speed of tooling development and performance. An extensive review of the suitable development approach of hybrid mold inserts, material preparation and filler effect on physical and mechanical properties has been conducted. Findings Latest research studies indicate that it is possible to develop a hybrid material through the combination of different shapes/sizes of filler particles and it is expected to improve the compressive strength, thermal conductivity and consequently increasing the hybrid mold performance (cooling time and a number of molding cycles). Research limitations/implications The number of research studies on RT for hybrid mold inserts is still lacking as compared to research studies on conventional manufacturing technology. One of the significant limitations is on the ways to improve physical and mechanical properties due to the limited type, size and shape of materials that are currently available. Originality/value This review presents the related information and highlights the current gaps related to this field of study. In addition, it appraises the new formulation of MEC materials for the hybrid mold inserts in injection molding application and RT for non-metal products.

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The role of nanocrystalline binder metallic coating into WC after additive manufacturing

Cited by 18 publications

References 18 publications

Process development for the laser powder bed fusion of WC‐Ni Cermets using sintered‐agglomerated powder

Process development for the laser powder bed fusion of WC‐Ni Cermets using sintered‐agglomerated powder

Additive Manufacturing of Cemented Tungsten Carbide with a Cobalt-Free Alloy Binder by Selective Laser Melting for High-Hardness Applications

The potential of metal epoxy composite (MEC) as hybrid mold inserts in rapid tooling application: a review

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