Exploring laser-material interactions of zirconium carbide under additive manufacturing conditions

Wilson-Heid, Alexander E.; Griffiths, R. Joey; Martin, Aiden A.; Holliday, Kiel S.; Jeffries, Jason R.

doi:10.1016/j.ceramint.2024.04.051

Title: Exploring laser-material interactions of zirconium carbide under additive manufacturing conditions

Journal Article · 05 April 2024 · Ceramics International

DOI: https://doi.org/10.1016/j.ceramint.2024.04.051 · OSTI ID:2406143

^[1]; Griffiths, R. Joey ^[1];

^[1]; Holliday, Kiel S. ^[1]; Jeffries, Jason R. ^[1]

Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)

Zirconium carbide (ZrC) is an ultra-high temperature ceramic with a melting temperature above 3000°C and a broad range of high temperature applications. Given the high melting and sintering temperatures of pure ZrC, producing near-net shape and fully dense parts remains challenging with conventional techniques. In this study, we investigate the fundamental laser-material interactions of ZrC under laser powder bed fusion (LPBF) additive manufacturing (AM) conditions. Normalized enthalpy, a scaling law term that is used in welding and AM literature for detailing laser-material interactions in metallic alloys, was calculated to determine the predictive capabilities of melt pool features in ZrC. Further, the melt pool quality of laser irradiated ZrC was used to compare LPBF relevant laser parameter combinations of laser power, scan speed, and beam diameter. Laser build parameters that resulted in desirable melt pool morphologies were applied to the fabrication of ZrC coupons using LPBF AM. A custom LPBF system was used to determine hatch spacing and layer height parameters that resulted in a fabricated sample with a density of 85% as measured by Archimedes and a Vicker's microhardness of 20.9 ± 1.9 GPa. This investigation reveals the laser-material interactions of ZrC under AM relevant conditions and is the first step towards LPBF fabrication of ZrC parts.

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Research Organization:: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: AC52-07NA27344

OSTI ID:: 2406143

Report Number(s):: LLNL-JRNL-845019; 1068239

Journal Information:: Ceramics International, Journal Name: Ceramics International Journal Issue: 13 Vol. 50; ISSN 0272-8842

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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36 MATERIALS SCIENCE
Additive manufacturing
Laser powder bed fusion
Normalized enthalpy
Ultra-high temperature ceramics
Zirconium carbide

Title: Exploring laser-material interactions of zirconium carbide under additive manufacturing conditions

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