Wayland and Fraunhofer IFAM demonstrate crack-free tungsten AM
Wayland Additive, headquartered in Huddersfield, UK, and Fraunhofer IFAM, based in Dresden, Germany, have reported progress in the Additive Manufacturing of tungsten using Wayland’s Calibur3 Electron Beam Powder Bed Fusion (PBF-EB) machine. The collaboration has showcased the production of high-density, crack-free tungsten parts, including complex geometries.
Tungsten has the highest melting point of any metal, at 3,422°C, making it suitable for applications requiring resistance to extreme temperatures. Its high thermal stability, wear resistance and density offer further benefits, although these properties also present manufacturing challenges.
The partners have been investigating the use of Wayland’s NeuBeam technology and Active Charge Neutralisation (ACN) to process tungsten. According to Wayland, the technology enables the production of complex geometries, including parts built ‘free-floating’ within the powder bed, without being attached to the build platform.
Fraunhofer IFAM has released images of a demonstration rocket nozzle produced on its Calibur3 system. Designed by Wayland Application Engineer Keegan Duarte, the component illustrates the potential of the process for producing tungsten parts for high-temperature applications.
Wayland reports that residual powder can be removed from the manufactured parts within minutes, with no further critical post-processing, such as electrical discharge machining (EDM) or heat treatment, required. Polishing remains optional.
Trials to date have focused on achieving high-density, crack-free builds. The next stages of development will concentrate on improving productivity, evaluating alternative powders and producing more challenging geometries.
