Gradient Process Parameters-Microstructure-Compression Performance of the 98W Alloy Fabricated by Dual Laser Powder Bed Fusion

CHEN Tao; WANG Liang; DAI Donghua

doi:10.3969/j.issn.1674-6457.2026.05.018

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (5) : 188-199. DOI: 10.3969/j.issn.1674-6457.2026.05.018

Refractory Metal Forming

Gradient Process Parameters-Microstructure-Compression Performance of the 98W Alloy Fabricated by Dual Laser Powder Bed Fusion

CHEN Tao^1,2, WANG Liang^1,2, DAI Donghua^1,2,*

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Abstract

To solve the problems of porosity and cracking in the Single Laser Powder Bed Fusion (SL-PBF) additive manufacturing of high-density 98W alloy, the work aims to propose a Dual Laser Powder Bed Fusion (DL-PBF) integrated forming technology for high-density 98W alloy to achieve high-quality forming of thin-walled hemispherical structures. The effects of support types (block support and grid support) and process parameters on the residual porosity, microstructure, residual stress, and dimensional accuracy along the height direction of the 1/8 spherical structure (wall thickness 3 mm) of high-density 98W alloy were studied to determine the support type and optimal process parameters for DL-PBF forming high-density 98W alloy hemispherical shell structures. It was found that block support could easily cause protruding defects at the top of the structure, and small equiaxed crystals (size 13.8 μm) were formed in the bottom region, while columnar crystals (size 16.9 μm) were formed in the top region. Under the optimized process parameters, the ultimate compressive strength and compression ratio of the 98W alloy formed by DL-PBF were 2 262.3 MPa and 38.5%, respectively. When the laser power was high (P=225 W), larger residual pores were easily generated at the top of the structure, and the wall thickness changed significantly along the height direction (maximum wall thickness 3.4 mm and minimum wall thickness 3.32 mm). When the laser power was appropriate (P=195 W), the cross section of the structure was nearly dense without microcracks, and the average wall thickness was 3.25 mm. Based on the evolution law of heat accumulation and residual pores in the 1/8 spherical structure, a height-direction gradient energy density strategy is proposed, which realizes the stable forming of the hemispherical structure with a wall thickness of 4 mm and a height of 40 mm, providing data support for the high-quality forming of high-density complex 98W alloy structures.

Key words

DL-PBF / 98W alloy / microstructure / compressive performance / gradient energy process / hemispherical structure

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CHEN Tao, WANG Liang, DAI Donghua. Gradient Process Parameters-Microstructure-Compression Performance of the 98W Alloy Fabricated by Dual Laser Powder Bed Fusion[J]. Journal of Netshape Forming Engineering. 2026, 18(5): 188-199 https://doi.org/10.3969/j.issn.1674-6457.2026.05.018

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Funding

The Defense Industrial Technology Development Program (JCKY2022212C002); Natural Science Foundation of Jiangsu Province (BK20250174); Development in Key areas of Guangdong Province (2023B0909020004); Project of Innovation Research Team in Zhongshan (CXTD2023006)