Cracking mechanisms in additively manufactured pure tungsten from printing single tracks, thin walls and cubes

Cracking is a critical issue in the additive manufacturing of pure tungsten (W). To eliminate crack formation, it is imperative to gain an in-depth understanding of the underlying mechanisms behind this process. In this study, we systematically investigated the crack behaviors of single tracks, thin walls, and cubes fabricated using powder bed fusion–laser beam (PBF–LB) technology with nonrotational parallel-hatching scanning. The energy framework was employed to elucidate the mechanism of crack formation. The longitudinal cracks appearing in the microstructures of single tracks and the through cracks existing in thin walls and cubes were characterized. Notably, periodic through cracks extended upward across the sample, appearing at every single hatch in unidirectional samples and at every other hatch in bidirectional samples. The horizontal, longitudinal, and transverse cross sections of cubes were studied to clarify the correlation between through crack arrangement and solidification microstructure. Based on a comprehensive analysis of grain boundaries, we proposed a deformation-cracking competition mechanism in PBF–LB tungsten. Geometric effects in the crack and microstructure were also revealed. This study could provide valuable insights into the formation of cracks in PBF–LB tungsten and serve as a foundation for future investigations aimed at eliminating cracks.