Laser-Based Additive Manufacturing of Zirconium

Additive manufacturing of zirconium is attempted using commercial Laser Engineered Net Shaping (LENSTM) technique. A LENSTM-based approach towards processing coatings and bulk parts of zirconium, a reactive metal, aims to minimize the inconvenience of traditional metallurgical practices of handling and processing zirconium-based parts that are particularly suited to small volumes and one-of-a-kind parts. This is a single-step manufacturing approach for obtaining near net shape fabrication of components. In the current research, Zr metal powder was processed in the form of coating on Ti6Al4V alloy substrate. Scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) as well as phase analysis via X-ray diffraction (XRD) were studied on these coatings. In addition to coatings, bulk parts were also fabricated using LENS (TM) from Zr metal powders, and measured part accuracy.