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The manufacturing of refractory-metals components presents some limitationsinduced by the materials characteristic low-temperature brittleness and highsusceptibility to oxidation. Powder metallurgy is typically the manufacturingprocess of choice. Recently, Wire + Arc Additive Manufacturing has provencapable to produce fully-dense large-scale metal parts at relatively low cost,by using high-quality wire as feedstock. In this study, this technique has beenused for the production of large-scale tungsten linear structures. Theorientation of the wire feeding has been studied and optimised to obtaindefect-free tungsten deposits. In particular, front wire feeding eliminated theoccurrence of pores and micro-cracks, when compared to side wire feeding. Themicrostructure, the occurrence of defects and their relationship with thedeposition process have also been discussed. Despite the repetitive thermalcycles and the inherent brittleness of the material, the as-depositedstructures were free from internal cracks and the layer dimensions were stableduring the entire deposition process. This enabled the production of arelatively large-scale component, with the dimension of 210 x 75 x 12 mm. Thisstudy has demonstrated that Wire + Arc Additive Manufacture can be used toproduce large-scale parts in unalloyed tungsten by complete fusion, presentinga potential alternative to the powder metallurgy manufacturing route.

Development of Wire + Arc Additive Manufacturing for the production of large-scale unalloyed tungsten components