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In a significant breakthrough for the field ofadditive manufacturing, a team of scientists from Hiroshima University has developed a method to effectively 3D print one of the hardest materials known in engineering: tungsten carbide-cobalt (WC-Co). This innovation addresses the challenges associated with ultra-hard materials and promises to reduce waste and costs compared to conventional manufacturing methods.
The toughness of materials like WC-Co has made them essential in industries requiring durability, such as cutting and construction tools. Traditional methods of producing these materials often result in substantial waste and economic burdens. However, the new approach leverages a unique technique that softens rather than fully melts the material, facilitating a more efficient production process.
The hot-wire laser irradiation method
Central to this innovative technique is thehot-wire laser irradiation method. This approach employs a combination of laser beams and pre-heated filler wires to gradually soften a cemented carbide rod. This allows for layer-by-layer construction without the drawbacks associated with complete melting. The meticulous control of temperature during this process ensures that the material maintains its high hardness levels, achieving a hardness rating exceeding1400 HV, just below that of materials like sapphire and diamond.
Process refinement and challenges
Despite the promising results, the research team acknowledges existing challenges. Issues such as cracking have been encountered, which could compromise the structural integrity of the final products. To address these concerns, researchers are exploring various refinements to their process, aiming to produce more complex shapes while maintaining the desired durability. The inclusion of a nickel alloy-based middle layer has proven beneficial in achieving defect-free production and enhancing the
Future implications and applications
The implications of this research extend beyond tungsten carbide. The novel methodology of softening metal materials has the potential to be adapted for a range of other substances, paving the way for advancements in various manufacturing sectors. As industries continue to seek methods that optimize resource use while maintaining quality, this technique represents a significant step forward.
As researchers likeKeita Marumoto, an assistant professor at Hiroshima University, emphasize, the goal is not only to refine the current process but also to explore its application in fabricating cutting tools and other high-performance materials. This could lead to significant reductions in material costs and waste in manufacturing, further solidifying the role of additive manufacturing in modern engineering.