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Binder Jet Additive Manufacturing of Tungsten Carbide-Cobalt Tooling MaterialPatel, Kunal Balkrishnabhai 12 1900 (has links)
This research investigated the binder jet additive manufacturing (BJAM) of WC-10 wt.%Co, emphasizing the evolution of phase and microstructure throughout BJAM densification techniques. The BJAM process was first optimized by setting a layer thickness of 124 μm and a binder saturation level of 60%. Initial samples were fabricated using coarse WC particles (D50 - 28 μm) and fine Co particles. Printed parts underwent a curing step at 200°C to enhance green density, enabling part stability. Subsequently, debinding removed the binder to eliminate any residuals before densification techniques. BJAM densification techniques included sintering, hot isostatic pressing (HIP), and pack carburizing. The phases and microstructure in the fabricated parts were examined via X-ray diffraction, scanning electron microscopy, electron backscatter diffraction, energy-dispersive x-ray spectroscopy, and hardness measured by Vickers hardness testing. BJAM printed WC-10 wt.%Co samples achieved 77% and 82% density following sintering and HIP, respectively. XRD revealed the presence of undesirable η phases after sintering and sinter+HIP. Moreover, EBSD observations confirmed the grain coursing during the densification techniques. The pack carburizing step effectively decomposed the η phase, reverting it to the desirable WC phase. This transformation also resulted in improved hardness for carburized samples compared to sintered and sintered+HIPed samples. However, there was no significant change in the density after pack carburizing. This study demonstrated the feasibility of using BJAM for WC-Co alloys, highlighting the effectiveness of pack carburizing in refining phase composition by η phase decomposition into the WC phase.
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