Selective Laser Melting Additive Manufactured Tantalum: Effect of Microstructure and Impurities on the Strengthening-Toughing Mechanism

The balance between the strength and the toughness of pure tantalum (Ta) fabricated with selective laser melting (SLM) additive manufacturing is a major challenge due to the defect generation and affinity for oxygen and nitrogen. This study investigated the effects of energy density and post-vacuum annealing on the relative density and microstructure of SLMed tantalum. The influences of microstructure and impurities on strength and toughness were mainly analyzed. The results indicated that the toughness of SLMed tantalum significantly increased due to a reduction in pore defects and oxygen-nitrogen impurities, with energy density decreasing from 342 J/mm to 190 J/mm . The oxygen impurities mainly stemmed from the gas inclusions of tantalum powders, while nitrogen impurities were mainly from the chemical reaction between the molten liquid tantalum and nitrogen in the atmosphere. The proportion of texture decreased after vacuum-annealing at 1200 °C, while that of the texture increased. Concurrently, the density of dislocations and small-angle grain boundaries significantly decreased while the resistance of the deformation dislocation slip was significantly reduced, enhancing the fractured elongation up to 28% at the expense of 14% tensile strength.