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| Freemelt AB Tungsten Powder |
Breakthrough in PBF-EB Processing of Chemically Reduced Tungsten
Freemelt AB, based in Mölndal, Sweden, has achieved a significant milestone by processing chemically reduced tungsten powder into nearly fully dense material with 99.8–99.9% density. This development uses their proprietary Freemelt ONE Electron Beam Powder Bed Fusion (PBF-EB) additive manufacturing system. The achievement, verified by researchers from Mid Sweden University, UPC Barcelona, Sandvik, Wolfram, and Freemelt, highlights new possibilities for tungsten in high-temperature sectors such as defense, energy, and medical technology.
The research utilized both line and spot melting techniques, applying gradient variations in beam current, scanning speed, and dwell time to optimize the fusion process. This innovative approach mapped the transition between porous and swelling tungsten within prismatic test specimens. Consequently, the team identified precise processing parameters that yield dense, swelling-free tungsten samples, critical for structural integrity in demanding industrial applications.
Advanced Characterization and Industrial Implications
The tungsten samples reached 99.8% and 99.9% density according to the Archimedes method, confirming exceptional consolidation. Detailed microstructural analyses through SEM and EBSD revealed consistent grain structure and chemical homogeneity, while microhardness testing verified local mechanical robustness. However, scaling line melting proved impractical due to warping, leading researchers to scale spot melting up to 50 mm × 50 mm successfully.
This advancement directly supports industries that require tungsten’s exceptional high-temperature stability and mechanical performance. Moreover, it enhances additive manufacturing’s role in producing complex tungsten components, potentially reducing lead times and material waste. Freemelt’s PBF-EB process now stands as a promising pathway for the recycling and reuse of chemically reduced tungsten powders in critical global markets.
ScrapInsight Commentary
This breakthrough in PBF-EB of chemically reduced tungsten signals a leap forward for the scrap tungsten market and circular economy. The near-full densification allows scrap tungsten powders to re-enter high-value manufacturing streams, reducing reliance on virgin materials. Consequently, tungsten pricing may stabilize as recycled content grows. Regulatory frameworks promoting sustainable metal reuse will likely accelerate adoption in energy and defense sectors.
