# Collaborative Research: Additive Manufacturing of Crack-Free Tungsten Using Ultrashort Pulsed Lasers

> **NSF 01002526DB NSF RESEARCH & RELATED ACTIVIT** · University of Tennessee Knoxville (TN) · $175,000

## Abstract

Additive manufacturing (AM) with lasers is a method of creating 3-dimensional structures by fusing layers of material together. However, building with tungsten using traditional continuous lasers often leads to cracking because these lasers generate too much heat over a large area. Initial experiments show that using ultrashort pulsed lasers, which release energy in tiny bursts, can prevent cracking by limiting the heat to a very small area. While this approach looks promising, more research is needed to fully understand how it works. This project will conduct experiments and develop strategies to eliminate cracking when working with high-temperature materials. These improvements are vital for advancing technologies in aerospace, automotive, energy, and healthcare industries. In addition, the team plans to create educational programs and outreach activities to train future engineers, equipping them with the skills needed to lead in advanced manufacturing.

The overarching goal of this project is to achieve crack-free additive manufacturing (AM) of tungsten using a femtosecond (FS) laser. The high ductile-to-brittle transition temperature of tungsten makes the metal vulnerable to cracking, particularly in AM processes. Based on the hypothesis that the thermal response to FS laser can induce tungsten conditions favorable for crack-free AM, the team will conduct a combination of experiments and physics-based simulations to identify such conditions for crack-free AM. This proje

## Key facts

- **NSF award ID:** 2412544
- **Awardee organization:** University of Tennessee Knoxville (TN)
- **SAM.gov UEI:** FN2YCS2YAUW3
- **PI:** Anming Hu
- **Primary program:** 01002526DB NSF RESEARCH & RELATED ACTIVIT
- **All programs:** MATERIALS DESIGN, MATERIALS PROCESSING AND MANFG, Advanced Manufacturing, MANUFACTURING
- **Estimated total:** $175,000
- **Funds obligated:** $175,000
- **Transaction type:** Standard Grant
- **Period:** 09/01/2025 → 08/31/2026

## Primary source

NSF Award Search: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2412544

## Citation

> US National Science Foundation, Award 2412544, Collaborative Research: Additive Manufacturing of Crack-Free Tungsten Using Ultrashort Pulsed Lasers. Retrieved via AI Analytics 2026-06-08 from https://api.ai-analytics.org/grant/nsf/2412544. Licensed CC0.

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