Students: Bartlomiej Bancewicz & Tyler Christ
Project: 3-D Printing of Tungsten Heavy Alloys | View Poster (PDF)
Institution: Lehigh University
Major: Materials Science and Engineering
Advisor: Wojciech Misiolek, Richard Vinci
Abstract
The goal of this study was to compare the effects of processing parameters on final properties of tungsten-heavy alloys (WHA). Mixed and pre-alloyed powders of WHA (93W–5.6Ni-1.4Fe) were 3D-printed in a Renishaw AM 400, using the selective laser melting (SLM) technique. The powders were printed with varied laser power and exposure times, for layer thicknesses of 20 and 30 μm. Laser power ranged 200-400 Watts, and exposure times ranged 400-800 µs. Optical density was highest for pre-alloyed WHA parts, printed at longer exposure times. Tungsten is a refractory metal with melting temperature 3,422°C. Therefore, longer exposure times are essential for a complete melting of WHA during SLM. Our density results did not improve for increased laser powers. Instead, higher power introduced significant cracking in printed parts. Mixed powder printed best at 20 μm layer thickness, whereas pre-alloyed printed best at 30 μm. This was expected due to the greater packing density and flowability of pre-alloyed powders.
About Bartlomiej Bancewicz
Bartlomiej Bancewicz is a senior in the Materials Science & Engineering major, pursuing a minor in Nanotechnology. He joined the Loewy Institute under Professor Misiolek during the 2017-2018 academic year, focusing on additive manufacturing research of tungsten and stainless steel alloys. In June 2018, he was awarded an NSF grant to present research at the PowderMET2018 conference in San Antonio, TX. This was an excellent opportunity that broadened his view of the powder metallurgy and additive manufacturing industries. After graduation, Bart will carry his Materials Science background into an M.S. in Environmental Engineering. Bart believes in a sustainable future, and his spare time is spent outside through walking, playing guitar, drawing, and writing. He is also a member of Lehigh’s Track & Field team, with a primary focus on the 800 m dash.
About Tyler Christ
Tyler Christ is a junior Materials Science and Engineering major with a minor in Business. He joined the Loewy Institute under Professor Misiolek and conducts research in additive manufacturing, with a concentration in selective laser melting (SLM). Within the Loewy Institute, Tyler has researched SLM for tungsten and 316L steel. SLM is an area of interest for Tyler because he believes it is the future of metal manufacturing. One of Tyler’s hobbies is swimming, and throughout college he has maintained his love for the sport as a member of the Lehigh Swimming & Diving team, and as a lifeguard at Taylor Gym for Lehigh Recreational Athletic. Tyler was chosen by his coaches to take part in the Flight 45 leadership training program and is now a Legacy of the swim team.
