Showing papers on "Tungsten published in 2019"

Outstanding radiation resistance of tungsten-based high-entropy alloys.

Abstract: A body-centered cubic W-based refractory high entropy alloy with outstanding radiation resistance has been developed. The alloy was grown as thin films showing a bimodal grain size distribution in the nanocrystalline and ultrafine regimes and a unique 4-nm lamella-like structure revealed by atom probe tomography (APT). Transmission electron microscopy (TEM) and x-ray diffraction show certain black spots appearing after thermal annealing at elevated temperatures. TEM and APT analysis correlated the black spots with second-phase particles rich in Cr and V. No sign of irradiation-created dislocation loops, even after 8 dpa, was observed. Furthermore, nanomechanical testing shows a large hardness of 14 GPa in the as-deposited samples, with near negligible irradiation hardening. Theoretical modeling combining ab initio and Monte Carlo techniques predicts the formation of Cr- and V-rich second-phase particles and points at equal mobilities of point defects as the origin of the exceptional radiation tolerance.

Oxide-Mediated Formation of Chemically Stable Tungsten-Liquid Metal Mixtures for Enhanced Thermal Interfaces.

Abstract: Modern microelectronics and emerging technologies such as wearable devices and soft robotics require conformable and thermally conductive thermal interface materials to improve their performance and longevity. Gallium-based liquid metals (LMs) are promising candidates for these applications yet are limited by their moderate thermal conductivity, difficulty in surface-spreading, and pump-out issues. Incorporation of metallic particles into the LM can address these problems, but observed alloying processes shift the LM melting point and lead to undesirable formation of additional surface roughness. Here, these problems are addressed by introducing a mixture of tungsten microparticles dispersed within a LM matrix (LM-W) that exhibits two- to threefold enhanced thermal conductivity (62 ± 2.28 W m-1 K-1 for gallium and 57 ± 2.08 W m-1 K-1 for EGaInSn at a 40% filler volume mixing ratio) and liquid-to-paste transition for better surface application. It is shown that the formation of a nanometer-scale LM oxide in oxygen-rich environments allows highly nonwetting tungsten particles to mix into LMs. Using in situ imaging and particle dipping experimentation within a focused ion beam and scanning electron microscopy system, the oxide-assisted mechanism behind this wetting process is revealed. Furthermore, since tungsten does not undergo room-temperature alloying with gallium, it is shown that LM-W remains a chemically stable mixture.

Molybdenum and tungsten manufactured by selective laser melting: Analysis of defect structure and solidification mechanisms

Abstract: In this work, processing of molybdenum and tungsten by Selective Laser Melting (SLM) is analyzed. The study reveals the impact of the oxygen content of the powder, the process atmosphere and the temperature of the substrate plate on the structural and mechanical properties of the processed material. For clarifying the causes and mechanisms for the formation of defects in molybdenum and tungsten processed by SLM, the samples were examined by x-ray, scanning and transmission electron microscopy including elemental distribution maps and crystallographic analyses by electron backscatter diffraction. Impurities, mainly oxygen, were identified as cause for the predominant defect structure comprising cracks and residual porosity. During processing, oxygen in the form of molybdenum/tungsten oxide, segregates at the grain boundaries, thereby inducing hot cracking. This is due to the lower melting point of the eutectic compared to the matrix phase. Moreover, the oxygen impurities were found to weaken the grain boundaries and thus increasing the risk for cold cracking and leading to a higher Ductile-to-Brittle Transition Temperature (DBTT). Subsequently, the combination of cracks through hot cracking at planar solidified grain boundaries and cold cracking along weakened grain boundaries during rapid cooling from the melting point creates the crack network generally found in molybdenum and tungsten processed by SLM. Also a substrate plate temperature of 1000 °C does not prevent the formation of cracks in tungsten caused by oxygen segregations.

Additive manufacturing of pure tungsten by means of selective laser beam melting with substrate preheating temperatures up to 1000 ∘C

Abstract: The preferred plasma-facing material in present-day and future magnetic confinement thermonuclear fusion devices is tungsten. This material is mainly chosen because of its high threshold energy for sputtering by hydrogen isotopes as well as its low retention of tritium within the material. From an engineering point of view, however, tungsten is a challenging material to work with as it is an inherently hard and brittle metal. In this respect, established fabrication technologies for tungsten and tungsten based materials are a limiting factor directly affecting the design of plasma-facing components. Against this background, additive manufacturing technologies could prove very beneficial with regard to plasma-facing component applications as they offer flexibilities beyond the possibilities that conventional manufacturing methods offer. Within the present contribution, we report on recent results regarding the additive manufacturing of tungsten by means of powder-bed based selective laser beam melting. In more detail, investigations on pure tungsten manufactured by using elevated substrate preheating temperatures up to 1000 ∘C are described.

Machine-learning interatomic potential for radiation damage and defects in tungsten

Abstract: Tungsten will be used as a plasma-facing material in fusion power reactors, where the absorption of high-energy neutrons leads to permanent damage in the crystal structure. A comprehensive understanding of the atom-level damage in tungsten has been limited by the slowness of quantum simulations and the insufficient accuracy of classical simulations. This study bridges the gap between the two by developing a machine-learning interatomic potential that allows the simulation of tungsten in extreme environments with quantum accuracy.

Selective laser melting additive manufacturing of pure tungsten: Role of volumetric energy density on densification, microstructure and mechanical properties

Abstract: Due to the intrinsic properties of tungsten, such as high melting point and high thermal conductivity, selective laser melting of pure W parts experiences many challenges. In this study, the effects of volumetric energy density on the densification behavior, microstructure evolution and mechanical performances of SLM-processed pure tungsten parts were investigated. A maximum density of 19.0 g/cm3 (98.4% of the theoretical density) was obtained at the optimal energy density of 1000 J/mm3 and its microstructure was free of pores and balling phenomenon. The formation mechanism of pores and cracks was systematically investigated. The microhardness and compressive strength of SLM-processed pure W parts reached 474 HV and 902 MPa, respectively, which were comparable to the samples produced by conventional manufacturing methods. The morphology of fracture demonstrated that the fracture mechanism of SLM-processed pure W parts was brittle fracture and intergranular fracture was the main fracture mode. Dry sliding wear tests showed that the wear mechanism changed with the energy density. For pure W parts processed by SLM at the optimal parameters, the adhesion of hardened tribolayers was formed. In this case, the reduced coefficient of friction (COF) of 0.45 and a low wear rate of 1.3 × 10−5 mm3·N−1·m−1 were obtained.

Effect of processing parameters on the densification, microstructure and crystallographic texture during the laser powder bed fusion of pure tungsten

Abstract: Laser Powder Bed Fusion is a leading additive manufacturing technology, which has been used successfully with a range of lower melting point materials (titanium alloys, nickel alloys, steels). This work looks to extend its use to refractory metals, such as those considered in this paper where the behaviour of pure tungsten powder is investigated. A strategy for fabricating high density parts was developed by creating a process map in which the effect of laser energy density was studied. The process quality was assessed using different techniques including light optical microscopy, XCT, SEM and EBSD. The results showed that the laser energy density was adequate to process tungsten to produce functional parts. The bulk density and optically determined densities, under different process conditions, ranged from 94 to 98%, but there was evidence of micro cracks and defects in specimens due to micro- and macro-scale residual stress. Analysis of the microstructure and local crystallographic texture showed that the melt pool formed under the laser beam favoured solidification in a preferred orientation by an epitaxial growth mechanism. The EBSD local texture analysis of the tungsten specimens showed a //Z preferential fibre texture, parallel to the build direction.

Arc erosion behavior of the Al2O3-Cu/(W, Cr) electrical contacts

Abstract: Al2O3-Cu/(25)W(5)Cr and Al2O3-Cu/(35)W(5)Cr electrical contact materials were fabricated by vacuum hot-pressing sintering and internal oxidation. The relative density, electrical conductivity, and Brinell hardness were measured. The microstructure was analyzed by scanning electron microscopy and transmission electron microscopy. JF04C electrical contact testing apparatus were used to investigate the electrical contact performance of composites. Arc erosion morphologies were analyzed by scanning electron microscopy and three-dimensional profilometer. The material transfer as well as electrical contact performance were studied during contact make and break operations at 30 V DC with current between 10 and 30 A. It indicates that the nano-Al2O3 particles pinned dislocations. Material transfers from the cathode to the anode. With the melting, evaporation, and sputtering of Cu during arcing, W particles gather and generate needle-shaped skeletons. Finally, liquid droplets, needle-like structures, craters, and bulges were formed on electrode surfaces after arc erosion. Furthermore, their quantity and morphology are affected by tungsten content. When the content of W in the dispersed copper matrix increases from 25 wt% to 35 wt%, welding force is reduced during the steady operations. In addition, when the arc duration is greater than 8.86 ms, the Al2O3-Cu/(35)W(5)Cr contact material has a shorter average arc duration than Al2O3-Cu/(25)W(5)Cr at the same arc energy.

Rational Synthesis and Gas Sensing Performance of Ordered Mesoporous Semiconducting WO3/NiO Composites.

Abstract: Semiconducting metal oxides have attracted increasing attention in various fields due to their intrinsic properties. In this study, a facile solvent evaporation-induced multicomponent co-assembly approach coupled with a carbon-supported crystallization strategy is employed to controllably synthesize crystalline mesoporous nickel oxide-doped tungsten oxides in an acidic THF/H2O solution with poly(ethylene oxide)-b-polystyrene diblock copolymers (PEO-b-PS) as the structure-directing agent, tungsten(VI) chlorides as WO3 precursors, and Ni(AcAc)2 as the NiO precursor. The obtained materials possess a face-centered cubic mesoporous structure, large pore size (∼30 nm), high surface area (30-50 m2 g-1), large pore volume (0.15-0.19 cm3 g-1), and ultralarge pore windows (12-16 nm) connecting adjacent mesopores, and the mesoporous WO3 framework was decorated by ultrafine NiO nanocrystals. Due to their well-connected porous structure and high surface areas with rich WO3-NiO interfaces, the composite materials exhibit superior gas sensing performance with an ultrafast response (∼4 s), high sensitivity (Ra/Rg = 58 ± 5.1), and selectivity to 50 ppm H2S at a relatively low working temperature (250 °C). The chemical mechanism study reveals complicated surface reactions of WO3/NiO-based gas sensors, and SO2, WS2, and NiS intermediates were found to be generated during the gas sensing process.

Formation of scanning tracks during Selective Laser Melting (SLM) of pure tungsten powder: Morphology, geometric features and forming mechanisms

Abstract: Due to the high melting point and high heat conductivity, selective laser melting (SLM) of tungsten is still challenging. To have a better understanding of SLM tungsten parts, the effects of processing parameters such as laser power and scanning speed on scanning tracks formation of pure tungsten powder were investigated. As linear energy increased with increasing laser power and decreasing scanning speed, the height and contact angle of scanning tracks gradually reduced, while the width and penetration depth increased. Owing to the good wetting and spreading, the flow front of scanning tracks gradually became smooth and stable with the increased linear energy. However, the transverse cracks induced by large temperature gradient and high cooling rate appeared on the surface of the scanning tracks at linear energy of more than 1.75 J/mm. A maximum temperature of 4630.27 °C and high cooling rate of 8.6 × 106 °C/s were obtained during SLM process of tungsten powder when the linear energy was 1.75 J/mm. This work provides scientific guidance for SLM-processed tungsten parts.

High-density tungsten fabricated by selective laser melting: Densification, microstructure, mechanical and thermal performance

Abstract: High-density pure tungsten (W) fabricated by selective laser melting (SLM) has been considered as a substantial challenge due to its high melting point of 3410 °C. In this study, near fully dense W samples with a relative density of 98.71% were obtained for the first time through a series of optimization experiments during the SLM process. The characteristics of the surface and the formation mechanism of the micro defects were systematically elucidated. Additionally, it was found that the typical microstructures of horizontal and vertical planes experienced successive changes, where coarser columnar grains changed to uniform finer grains when increasing the laser scan speed from 50 mm/s to 400 mm/s. The compressive strength, micro hardness and thermal conductivity of the optimal SLM sample was improved to 1523 MPa, 428 HV3 and 148 W/m·K, which were superior to the sample produced by the conventional methods. The relationship of processing parameters to the surface morphology and microstructure evolution and material properties associated with fusion reactors was established in order to optimize the performance of SLM pure W and explore the possibility of further application in fusion reactors.

Development of Wire + Arc additive manufacture for the production of large-scale unalloyed tungsten components

Abstract: The manufacturing of refractory-metals components presents some limitations induced by the materials' characteristic low-temperature brittleness and high susceptibility to oxidation. Powder metallurgy is typically the manufacturing process of choice. Recently, Wire + Arc Additive Manufacture has proven capable to produce fully-dense large-scale metal parts at relatively low cost, by using high-quality wire as feedstock. In this study, this technique has been used for the production of large-scale tungsten linear structures. The orientation of the wire feeding has been studied and optimised to obtain defect-free tungsten deposits. In particular, front wire feeding eliminated the occurrence of pores and micro-cracks, when compared to side wire feeding. The microstructure, the occurrence of defects and their relationship with the deposition process have also been discussed. Despite the repetitive thermal cycles and the inherent brittleness of the material, the as-deposited structures were free from internal cracks and the layer dimensions were stable during the entire deposition process. This enabled the production of a relatively large-scale component, with the dimension of 210 × 75 × 12 mm. This study has demonstrated that Wire + Arc Additive Manufacture can be used to produce large-scale parts in unalloyed tungsten by complete fusion, presenting a potential alternative to the powder metallurgy manufacturing route.