Powder metallurgy has been the default manufacturing route for tungsten because of its scalability and process maturity. However, it carries fundamental constraints such as long lead times tied to tooling, multiple required processing steps and susceptibility to internal defects that limit design flexibility and performance in demanding applications.
Electron beam powder bed fusion (EB-PBF) offers an alternative route for manufacturing pure and alloyed tungsten parts. By processing tungsten layer by layer in a vacuum at elevated temperatures, EB-PBF avoids the oxidation, cracking and porosity mechanisms that complicate conventional tungsten manufacturing. Tungsten parts made with EB-PBF can be used for high-density, high-temperature applications such as hypersonics, kinetic penetrators and radiation shielding.
Agenda:
Powder metallurgy process for tungsten: Where it works well and what fundamental constraints limit part performance and design flexibility.
Electron beam powder bed fusion for tungsten: How a tungsten 3D printing process addresses challenges in cracking, oxidation and internal defects that have made tungsten manufacturing difficult.
Side-by-side comparative analysis: An evaluation of both manufacturing processes and which applications are most suitable for powder metallurgy versus EB-PBF.
Jonathan Buckley is an AM applications engineer for JEOL USA, supporting JEOL's additive manufacturing division. He has worked in the additive manufacturing industry for the past 10 years, primarily supporting electron beam powder bed fusion technologies. Buckley has experience both from supporting an EB-PBF machine manufacturer and from utilizing EB-PBF technology at an AM contract manufacturer focused on the production of additively manufactured orthopedic implants. He actively engages with the AM community through technical outreach including webinars, trade shows and industry events.
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