WC Grain Growth Behavior During Selective Laser Melting of WC-Co Cemented Carbides

doi:10.1007/s40195-023-01519-6

Abstract

Abstract:

Scanning strategy is a critical parameter for selective laser melting (SLM) processing of metals, alloys as well as metal-ceramic composites, while related research has rarely been reported yet, especially for additive manufacturing of WC-Co cemented carbides. In this study, three scanning strategies, i.e., stripe, checkerboard, and spiral scanning, were used for additive manufacturing of WC-32Co cemented carbides. Checkerboard scanning leads to the highest relative density of 96%. Stripe scanning results in the largest average WC grain size followed by checkerboard and spiral scanning. SLM-processed carbides demonstrate agglomeration of WC grains mixed with isolated Co pools and pores. The WC grain growth mechanisms of SLM-processed cemented carbides include mosaic agglomeration growth and incomplete and uneven step growth regardless of scanning strategies.

Key words: Cemented carbides, Selective laser melting, Scanning strategy, Grain, Microstructure

Jinyang Liu, Jian Chen, Yang Lu, Xin Deng, Shanghua Wu, Zhongliang Lu. WC Grain Growth Behavior During Selective Laser Melting of WC-Co Cemented Carbides[J]. Acta Metallurgica Sinica (English Letters), 2023, 36(6): 949-961.

Figures/Tables 15

Fig. 1 Typical granule morphology and granule size distribution of feedstock WC-Co powder: a SEM image of WC-Co granule, b granule size distribution curve

Fig. 2 Schematics of scanning strategies: a stripe scanning—Alloy A, b checkerboard scanning—Alloy B, and c spiral scanning—Alloy C

Table 1 Optimum SLM process parameters employed in this study

Parameter	Laser spot diameter (μm)	Scanning speed (mm/s)	Laser power (W)	Scan line spacing (μm)	Powder layer thickness (μm)
Symbol	ω	V	P	h	d
Value	60	350	180	40	30

Fig. 3 Checkerboard scanning strategy for SLM-processed WC-Co cemented carbides

Fig. 4 Traditional sintering process: a liquid-phase sintering, b hot-pressing sintering

Fig. 5 SLM-processed WC-32Co carbide samples per different scanning strategies

Fig. 6 Relative density of SLM-processed cemented carbides upon stripe scanning (Alloy A), checkerboard scanning (Alloy B), and spiral scanning (Alloy C)

Fig. 7 SEM microstructures at horizontal (perpendicular to the laser beam) cross sections for samples SLM-processed with a, b stripe scanning, c, d checkerboard scanning, e, f spiral scanning

Fig. 8 Microstructure of cemented carbides via a liquid- phase sintering, b hot-pressing sintering process

Fig. 9 High-magnification SEM of WC grains from SLM and traditional LPS-processed WC-32Co carbide: a Alloy A—stripe scanning, b Alloy B—checkerboard scanning, c Alloy C—spiral scanning, d traditional LPS

Fig. 10 WC grain size distribution of SLM and traditional processed cemented carbides: a SLM-processed cemented carbides and b traditional LPS and HPS processed cemented carbides

Fig. 11 a Schematic illustration of WC agglomerate coarsening mechanism during SLM process and b typical morphology of WC agglomeration with trapped residual pores and Co pools

Fig. 12 WC grain morphology evolution during SLM process upon a stripe scanning, b checkerboard scanning, c spiral scanning, and schematic morphology evolution of WC grains for d single layer and e multilayer

Fig. 13 WC grain growth modes in cemented carbides: a crystal structure of WC, b schematic graph of WC grain shape upon traditional LPS, c WC grain growth process

Fig. 14 Comparison of WC grain growth mechanisms between traditional LPS and SLM-processed carbides: a WC grain morphology and grain growth mode of traditional LPS-processed carbides, b WC grain morphology and grain growth mode of SLM-processed carbides

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