Advances in Laser Powder Bed Fusion of Tungsten, Tungsten Alloys, and Tungsten-Based Composites

In high-tech areas such as nuclear fusion, aerospace, and high-performance tools, tungsten and its alloys are indispensable due to their high melting point, low thermal expansion, and excellent mechanical properties. The rise of Additive Manufacturing (AM) technologies, particularly Laser Powder Bed Fusion (L-PBF), has enabled the precise and rapid production of complex tungsten parts. However, cracking and densification remain major challenges in printing tungsten samples, and considerable efforts have been made to study how various processing conditions (such as laser power, scanning strategy, hatch spacing, scan speed, and substrate preheating) affect print quality. In this review, we comprehensively discuss various critical processing parameters and the impact of oxygen content on the control of the additive manufacturing process and the quality of the final parts. Additionally, we introduce additive manufacturing-compatible W materials (pure W, W alloys, and W-based composites), summarize the differences in their mechanical properties, densification, and microstructure, and further provide a clear outlook for developing additive manufactured W materials.

Sub-nanometer-scale mapping of crystal orientation and depth-dependent structure of dislocation cores in SrTiO3

Defects in crystals play a fundamental role in modulating mechanical, electrical, luminescent, and magnetic behaviors of materials. However, accurate measurement of defect structures is hindered by symmetry breaking and the corresponding complex modifications in atomic configuration and/or crystal tilt at the defects. Here, we report the deep-sub-angstrom resolution imaging of dislocation cores via multislice electron ptychography with adaptive propagator, which allows sub-nanometer scale mapping of crystal tilt in the vicinity of dislocation cores and simultaneous recovery of depth-dependent atomic structure of dislocations. The realization of deep-sub-angstrom resolution and depth-dependent imaging of defects shows great potential in revealing microstructures and properties of real materials and devices.

Edge-dislocation-induced ultrahigh elevated-temperature strength of HfMoNbTaW refractory high-entropy alloys

Over 150 refractory high-entropy alloys (RHEAs) have been proposed in the last decade. Early alloys such as MoNbTaW and MoNbTaVW still show an unparalleled yield strength of approximately 400 MPa at 1600°C. However, RHEAs with even elevated high-temperature strength are necessary in aerospace vehicles and nuclear reactors to cope with advanced technology in the future. Here, solid-solution strengthening calculation and melting point prediction are combined to design single-phase RHEA for attaining ultrahigh strength at 1600°C. The results show that Hf_0.5MoNbTaW and HfMoNbTaW alloys after fully homogeneous treatment at 2100°C for 2 h reveal a homogenous body-centered cubic phase. HfMoNbTaW alloy exhibits a yield strength of 571 MPa at 1600°C, much higher than that of MoNbTaVW (477 MPa). It is found that a plateau of strength occurs from 800°C to 1200°C, which is important for raising the strength level of RHEAs at high temperatures. This strengthening mechanism is explained with the change of deformation mode from screw to edge dislocations, which contributes an edge-dislocation-induced strength. A similar alloy design strategy could be applied to develop more RHEAs with an ultrahigh strength level.

Influence of Carbon and Oxygen on the Core Structure and Peierls Stress of Screw Dislocation in Molybdenum

The plasticity and hardness of metals are largely dependent on how dislocation interacts with solute atoms. Here, taking bcc molybdenum (Mo) as the example, the interaction of interstitial solutes carbon (C) and oxygen (O) with screw dislocation, and their influences on the dislocation motion, have been determined using first-principles calculations and thermodynamic models. Due to the incompact atomic structure and variation of electronic states in the dislocation core, C and O will segregate from the bulk system to the dislocation region. Notably, the presence of C/O at the dislocation induces the reconstruction of the core structure, from an easy-core to hard-core configuration. This originates from the fact that the hard-core structure provides a larger available volume at the interstitial site than the easy-core structure and, thus, facilitates the dissolution of C and O. More importantly, the addition of C/O in the dislocation significantly increases the Peierls stresses and double-kink formation enthalpies of screw dislocation in Mo, from 1.91 GPa and 1.18 eV for C/O-free dislocation to 5.63/4.69 GPa and 1.77/1.58 eV for C/O-saturated dislocation. Therefore, these interstitial solutes have a pinning effect on the dislocation motion, and this effect becomes stronger with higher segregating levels. This work reveals the profound effect of interstitial solutes on the properties of the dislocation core and provides a fundamental factor to account for the interstitial solutes-related phenomena in bcc metals.

{110} Slip with {112} slip traces in bcc Tungsten

While propagation of dislocations in body centered cubic metals at low temperature is understood in terms of elementary steps on {110} planes, slip traces correspond often with other crystallographic or non-crystallographic planes. In the past, characterization of slip was limited to post-mortem electron microscopy and slip trace analysis on the sample surface. Here with in-situ Laue diffraction experiments during micro-compression we demonstrate that when two {110} planes containing the same slip direction experience the same resolved shear stress, sharp slip traces are observed on a {112} plane. When however the {110} planes are slightly differently stressed, macroscopic strain is measured on the individual planes and collective cross-slip is used to fulfill mechanical boundary conditions, resulting in a zig-zag or broad slip trace on the sample surface. We anticipate that such dynamics can occur in polycrystalline metals due to local inhomogeneous stress distributions and can cause unusual slip transfer among grains.

Correlation between critical temperature and strength of small-scale bcc pillars

Microcompression tests were performed on focused-ion-beam-machined micropillars of several body-centered-cubic metals (W, Mo, Ta, and Nb) at room temperature. The relationship between yield strength and pillar diameter as well as the deformation morphologies were found to correlate with a parameter specific for bcc metals, i.e., the critical temperature T(c). This finding sheds new light on the phenomenon of small-scale plasticity in largely unexplored non-fcc metals.