Laser-Assisted Surface Modification of Additively Manufactured WC-10Co Tools

Tungsten carbide and cobalt cutting tools require low surface roughness to improve cutting performance by reducing the wear from machining friction. While this is achieved by conventional manufacturing processes (pressing and sintering, grinding), with additive manufacturing processes it is more difficult (layer height, printing strategy). Since less costly and more sustainable solutions (without lubricants) are being studied as alternatives to conventional processes, a complementary technology (laser ablation) is suggested for the additive manufacturing of green WC-10Co. In this study, material extrusion (MEX) was used to produce green WC-10Co 3D objects, followed by laser ablation (50 W ytterbium fiber laser, 800–1100 nm wavelength) on their surface. Different laser strategies and parameters (power, speed, frequency, distance between lines, number of passages) were tested to find the most suitable. Most combinations were excluded by initial visual inspection, while the best ones were measured with a contact and non-contact profilometer. Further analysis was made on the composition and microstructure (with techniques such as Raman spectroscopy, scanning electron microscope, x-ray diffraction, and hardness indentation) to study what the interaction with the laser changed on the surface. Results show that with a combination of 50 W laser power, 1000 mm/s laser speed, 2000 kHz laser frequency, 0.1 mm distance between lines and three laser passages, it was possible to achieve a surface roughness of 0.6 µm (Sa) for the sintered WC-10Co, produced by MEX. No η-phase and graphite were detected, as well as microporosity and fissures.