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A large body of literature within the additive manufacturing (AM) communityhas focused on successfully creating stable tungsten (W) microstructures due tosignificant interest in its application for extreme environments. However,solidification cracking and additional embrittling features at grain boundarieshave resulted in poorly performing microstructures, stymying the application ofAM as a manufacturing technique for W. Several alloying strategies, such asceramic particles and ductile elements, have emerged with the promise toeliminate solidification cracking while simultaneously enhancing stabilityagainst recrystallization. In this work, we provide new insights regarding thedefects and microstructural features that result from the introduction of ZrCfor grain refinement and NiFe as a ductile reinforcement phase - in addition tothe resulting thermophysical and mechanical properties. ZrC is shown to promotemicrostructural stability with increased hardness due to the formation of ZrO2dispersoids. Conversely, NiFe forms into micron-scale FCC phase regions withina BCC W matrix, producing enhanced toughness relative to pure AM W. Acombination of these effects is realized in the WNiFe+ZrC system anddemonstrates that complex chemical environments coupled with the tuning of AMmicrostructures provides an effective pathway for enabling laser AM W materialswith enhanced stability and performance.

Alloying Effects on the Microstructure and Properties of Laser Additively Manufactured Tungsten Materials