Additive manufacturing and modeling of tungsten using high repetition high power femtosecond laser

Tungsten is a high-temperature material extensively used for aerospace, defence and nuclear energy, but its manufacturing is limited to powder metallurgy due to cracking associated with the intrinsic brittle-to-ductile transition. We propose to additively manufacture tungsten using a high repetition femtosecond laser and minimize the input energy for fusion. In this work, based on a thermal flow model, we first extracted some processing parameters by comparing the materials properties of tungsten with Al alloys. Then we validated these parameters with both the bead-on-plate experiment and laser powder-bed fusion. Based on these results, we further developed an analytic model based on the two-temperature model (TTM).