Infiltration studies of additive manufacture of WC with Co using binder jetting and pressureless melt method

Cramer, Corson L.; Nandwana, Peeyush; Lowden, Richard Andrew; Elliott, Amy M.

doi:10.1016/j.addma.2019.04.009

Title: Infiltration studies of additive manufacture of WC with Co using binder jetting and pressureless melt method

Abstract

Additive manufacturing (AM) of tungsten carbide-cobalt (WC-Co) is explored starting with WC preforms shaped with binder jet additive manufacturing (BJAM) followed by melt infiltration of Co. The research objective is to demonstrate the ability to net-shape WC-Co composites through BJAM of a WC preform followed by backfilling with cobalt via pressureless infiltration. This method also has the potential to minimize shrinkage and grain growth compared to other AM techniques. The effects of sintering, Co content, and infiltration time on the net shaping and properties of processed composites are shown. The best shaped material had an average grain size of 5.1 μm, 32 vol.% Co, density of 98.54% theoretical, fracture toughness of 23.2 MPa m^1/2, and hardness of 9.0 GPa. Data presented illustrates that the proposed approach results in favorable ceramic-metal (cermet) properties and is viable for fabricating cermets of other material combinations. Furthermore successful AM of cermets provides complex geometries, high throughout, and low costs.

Authors:

Cramer, Corson L. ^[1];

^[1];

^[1]

Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

Publication Date:: Mon Apr 15 00:00:00 EDT 2019

Research Org.:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Org.:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

OSTI Identifier:: 1515699

Alternate Identifier(s):: OSTI ID: 2325149

Grant/Contract Number:: AC05-00OR22725

Resource Type:: Accepted Manuscript

Journal Name:: Additive Manufacturing

Additional Journal Information:: Journal Volume: 28; Journal Issue: C; Journal ID: ISSN 2214-8604

Publisher:: Elsevier

Country of Publication:: United States

Language:: English

Subject:: 36 MATERIALS SCIENCE; Binder jet additive manufacturing; Cermet composite; Pressureless melt infiltration

Citation Formats


                    Cramer, Corson L., Nandwana, Peeyush, Lowden, Richard Andrew, and Elliott, Amy M. Infiltration studies of additive manufacture of WC with Co using binder jetting and pressureless melt method.  United States: N. p., 2019. 
Web.  doi:10.1016/j.addma.2019.04.009.

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                    Cramer, Corson L., Nandwana, Peeyush, Lowden, Richard Andrew, & Elliott, Amy M. Infiltration studies of additive manufacture of WC with Co using binder jetting and pressureless melt method.  United States.  https://doi.org/10.1016/j.addma.2019.04.009

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                    Cramer, Corson L., Nandwana, Peeyush, Lowden, Richard Andrew, and Elliott, Amy M. Mon .  
"Infiltration studies of additive manufacture of WC with Co using binder jetting and pressureless melt method".  United States.  https://doi.org/10.1016/j.addma.2019.04.009.  https://www.osti.gov/servlets/purl/1515699.

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@article{osti_1515699,

  title        = {Infiltration studies of additive manufacture of WC with Co using binder jetting and pressureless melt method},

  author       = {Cramer, Corson L. and Nandwana, Peeyush and Lowden, Richard Andrew and Elliott, Amy M.},

  abstractNote = {Additive manufacturing (AM) of tungsten carbide-cobalt (WC-Co) is explored starting with WC preforms shaped with binder jet additive manufacturing (BJAM) followed by melt infiltration of Co. The research objective is to demonstrate the ability to net-shape WC-Co composites through BJAM of a WC preform followed by backfilling with cobalt via pressureless infiltration. This method also has the potential to minimize shrinkage and grain growth compared to other AM techniques. The effects of sintering, Co content, and infiltration time on the net shaping and properties of processed composites are shown. The best shaped material had an average grain size of 5.1 μm, 32 vol.% Co, density of 98.54% theoretical, fracture toughness of 23.2 MPa m1/2, and hardness of 9.0 GPa. Data presented illustrates that the proposed approach results in favorable ceramic-metal (cermet) properties and is viable for fabricating cermets of other material combinations. Furthermore successful AM of cermets provides complex geometries, high throughout, and low costs.},

  doi          = {10.1016/j.addma.2019.04.009},

  journal      = {Additive Manufacturing},

  number       = C,

  volume       = 28,

  place        = {United States},

  year         = {Mon Apr 15 00:00:00 EDT 2019},

  month        = {Mon Apr 15 00:00:00 EDT 2019}

}

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Stress-induced phase transformation in shape memory ceramic nanoparticles
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Title: Infiltration studies of additive manufacture of WC with Co using binder jetting and pressureless melt method

Abstract

Citation Formats

Impact resistance of TiC-based cermets journal, December 2013

PIM continues its march to maturity journal, July 1998

Hardmetals and Cermets journal, August 1989

Preparation and sintering of WC–Co composite powders for coarse grained WC–8Co hardmetals journal, July 2014

Powder injection molding of WC–8%Co tungsten cemented carbide journal, December 2002

Three-dimensional printing of tungsten carbide–10wt% cobalt using a cobalt oxide precursor journal, January 2007

Obtaining Crack-free WC-Co Alloys by Selective Laser Melting journal, January 2016

Direct Selective Laser Sintering of Hard Metal Powders: Experimental Study and Simulation journal, March 2002

Synthesis of Nanostructured WC-Co Hardmetal by Selective Laser Melting journal, January 2017

3-D printing: The new industrial revolution journal, March 2012

A Review of Additive Manufacturing journal, January 2012

Wettability of tungsten carbide by liquid binders in WC–Co cemented carbides: Is it complete for all carbon contents? journal, January 2017

FeAl–TiC and FeAl–WC composites—melt infiltration processing, microstructure and mechanical properties journal, March 1998

Binder burnout and evolution of the mechanical strength of dry-pressed ceramics containing poly(vinyl alcohol) journal, August 2001

The Application of the Single-Edge Notched Beam to Fracture Toughness Testing of Ceramics journal, January 1974

Abnormal growth of faceted (WC) grains in a (Co) liquid matrix journal, September 1996

Near-nano WC–Co hardmetals: Will they substitute conventional coarse-grained mining grades? journal, July 2010

jPOR: An ImageJ macro to quantify total optical porosity from blue-stained thin sections journal, November 2011

Iron aluminide-titanium carbide composites by pressureless melt infiltration — Microstructure and mechanical properties journal, September 1996

Influence of temperature, grain size and cobalt content on the hardness of WC–Co alloys journal, May 1999

Effects of Co content and WC grain size on wear of WC cemented carbide journal, July 2006

Microstructure, hardness and toughness of nanostructured and conventional WC-Co composites journal, July 1998

Wear properties of sintered WC-12%Co processed via Binder Jet 3D Printing (BJ3DP) journal, January 2019

Fracture toughness of two phase WC-Co cermets journal, January 1994

Fracture toughness and fracture of WC-Co composites journal, October 1976

Reactive spark plasma sintering of binderless WC ceramics at 1500°C journal, March 2014

Cemented carbide phase diagrams: A review journal, July 2011

Modeling of infiltration kinetics for liquid metal processing of composites journal, February 1988

Estimate of the diffusion coefficient in Co based liquids journal, February 2000

A kinetic model for cobalt gradient formation during liquid phase sintering of functionally graded WC–Co journal, March 2008

Coarsening in Sintering: Grain Shape Distribution, Grain Size Distribution, and Grain Growth Kinetics in Solid-Pore Systems journal, November 2010

Densification and Grain Growth of Porous Alumina Compacts journal, December 1994

Stress-induced phase transformation in shape memory ceramic nanoparticles journal, December 2019

Impact resistance of TiC-based cermets
journal, December 2013

PIM continues its march to maturity
journal, July 1998

Hardmetals and Cermets
journal, August 1989

Preparation and sintering of WC–Co composite powders for coarse grained WC–8Co hardmetals
journal, July 2014

Powder injection molding of WC–8%Co tungsten cemented carbide
journal, December 2002

Three-dimensional printing of tungsten carbide–10wt% cobalt using a cobalt oxide precursor
journal, January 2007

Obtaining Crack-free WC-Co Alloys by Selective Laser Melting
journal, January 2016

Direct Selective Laser Sintering of Hard Metal Powders: Experimental Study and Simulation
journal, March 2002

Synthesis of Nanostructured WC-Co Hardmetal by Selective Laser Melting
journal, January 2017

3-D printing: The new industrial revolution
journal, March 2012

A Review of Additive Manufacturing
journal, January 2012

Wettability of tungsten carbide by liquid binders in WC–Co cemented carbides: Is it complete for all carbon contents?
journal, January 2017

FeAl–TiC and FeAl–WC composites—melt infiltration processing, microstructure and mechanical properties
journal, March 1998

Binder burnout and evolution of the mechanical strength of dry-pressed ceramics containing poly(vinyl alcohol)
journal, August 2001

The Application of the Single-Edge Notched Beam to Fracture Toughness Testing of Ceramics
journal, January 1974

Abnormal growth of faceted (WC) grains in a (Co) liquid matrix
journal, September 1996

Near-nano WC–Co hardmetals: Will they substitute conventional coarse-grained mining grades?
journal, July 2010

jPOR: An ImageJ macro to quantify total optical porosity from blue-stained thin sections
journal, November 2011

Iron aluminide-titanium carbide composites by pressureless melt infiltration — Microstructure and mechanical properties
journal, September 1996

Influence of temperature, grain size and cobalt content on the hardness of WC–Co alloys
journal, May 1999

Effects of Co content and WC grain size on wear of WC cemented carbide
journal, July 2006

Microstructure, hardness and toughness of nanostructured and conventional WC-Co composites
journal, July 1998

Wear properties of sintered WC-12%Co processed via Binder Jet 3D Printing (BJ3DP)
journal, January 2019

Fracture toughness of two phase WC-Co cermets
journal, January 1994

Fracture toughness and fracture of WC-Co composites
journal, October 1976

Reactive spark plasma sintering of binderless WC ceramics at 1500°C
journal, March 2014

Cemented carbide phase diagrams: A review
journal, July 2011

Modeling of infiltration kinetics for liquid metal processing of composites
journal, February 1988

Estimate of the diffusion coefficient in Co based liquids
journal, February 2000

A kinetic model for cobalt gradient formation during liquid phase sintering of functionally graded WC–Co
journal, March 2008

Coarsening in Sintering: Grain Shape Distribution, Grain Size Distribution, and Grain Growth Kinetics in Solid-Pore Systems
journal, November 2010

Densification and Grain Growth of Porous Alumina Compacts
journal, December 1994

Stress-induced phase transformation in shape memory ceramic nanoparticles
journal, December 2019