Resilient Additive Manufacturing of Tungsten via Electron Beam Powder Bed Fusion

Purpose and goal

The project aims to develop and validate a robust, industrially relevant EB-PBF process for additive manufacturing of tungsten. The objectives are to achieve at least 99.5% relative density with substantially reduced cracking, establish relationships between processing, microstructure and properties, and manufacture graded tungsten structures for copper infiltration. This will strengthen Sweden´s capacity to manufacture critical components for defence and energy applications.

Expected effects and result

The project will deliver a validated EB-PBF process window for tungsten, modelling tools for process optimisation, data linking processing, microstructure and defects, and guidelines for graded structures. A demonstrator combining dense tungsten, a lattice structure and initial copper infiltration will show the potential of W-Cu systems. The results will reduce development time, material waste and dependence on vulnerable supply chains, while laying the foundation for industrialisation.

Planned approach and implementation

The 18-month project involves LiU, Freemelt, Saab Dynamics and Hitachi Energy. Work includes defining requirements, EB-PBF parameter development for tungsten, modelling of heat balance and melt behaviour, and characterisation of microstructure and defects. Graded structures transitioning from dense tungsten to a lattice will then be designed and manufactured, followed by copper infiltration. Results will be assessed against industrial needs and used to define a path towards industrialisation.