When you buy an incandescent light bulb, you never know how long it will burn. Its service life is limited mainly by microscopic cracks in the tungsten filament. A simulation model for materials reveals crack formation before and after the drawing process.

Ideally, light bulbs last for 42 days in continuous operation – or so the manufacturers would have us believe. But the reality is not quite so lustrous: Some light bulbs do not burn out for years, but others last only a few days. Fine cracks in the tungsten filament, which eventually cause it to break, preclude a more uniform product quality. This is a problem also faced by Osram and Philips, the world’s biggest light bulb manufacturers. The industry has so far relied on trial and error to improve the drawing process for the filament. Production processes can be enhanced more strategically by simulating the material behavior. Supported by researchers from the Fraunhofer Institute for Mechanics of Materials IWM, the manufacturers are investigating the cracks and the resultant difficulties when spiraling the wire. Osram project manager Bernd Eberhard is confident that “Once we have more insight into the composition and behavior of the filament, we will be able to optimize and standardize our production processes.”

With an average diameter of 40 micrometers depending on the type of lamp, the tungsten filament is only about half as thick as a human hair. To reach this diameter, the wire has to be pulled repeatedly through a wire-drawing die that stretches it lengthwise and makes it progressively thinner. Depending how often the process is repeated, it may acquire a varying number of longitudinal cracks. Splits of this kind form primarily during the first stages of the drawing process, when the wire is thinned from almost four millimeters to only 0.3. The fine cracks grow longer when the wire is stretched further to a diameter of as little as five micrometers. This fact can be attributed to the tension that remains in the wire after drawing out, as IWM project manager Holger Brehm and his predecessor Sabine Weygand have discovered. “We have already succeeded in mathematically describing the behavior of the wire and the cracks that form during and after the drawing-out process. For the first time ever, the tungsten filament can be monitored on the screen during the entire thinning-out process.”

Crack formation is being further investigated and other decisive factors are integrated in the model. One such factor is the friction between the wire and the wire-drawing die. High friction makes the metal hotter. The researchers are therefore currently integrating the temperature change during and after drawing into their simulation. “The drawn wire cools faster on its surface than on the inside,” Brehm summarizes the latest experimental findings. “Unfortunately, splits can occur during this process as well.”

source from www.azom.com

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Background
Silver/Tungsten alloys containing between 25 and 50% silver are used for electrical contacts. These materials are produced via powder metallurgical techniques due to their widely different melting points.

Tungsten oxides and tungstates form on the surface of these metals. This can lead to increasing contact resistance over time.

If more arc resistance is required then these materials can withstand or if contact resistance becomes a problem, silver/tungsten carbide materials offer an alternative.
 
Key Properties
Silver/Tungsten metals combine the high thermal and electrical conductivities of silver with the arc resistance of tungsten.
 
Applications
As mentioned above, silver/tungsten materials are used for electrical contacts. Typically they are used in heavy duty devices subject to high currents. The presence of the refractory material tungsten, reduces the chances of welding and improves resistance to arc erosion. Optimal compositions are found by balancing conductivity and non-welding properties.

Devices that utilise silver/tungsten materials include:

•         Circuit breakers (often in the 50-100Amp range)

•         Relays that require good arc resistance
 

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Introduction
Hot work tool steels are steels capable of withstanding high abrasion, heat and pressure conditions that prevail in manufacturing units that perform processes such as forming, shearing and punching of metals at high temperatures of 480 to 760°C (900 to 1400°F). These steels have wear resistance up to 540°C (1000°F).

Hot work tool steels are designated as group H steels and they have 0.35% to 0.45% carbon, 6% to 25% chromium, with vanadium, molybdenum, and tungsten as the other alloying elements. Tungsten is primarily used in hot forming tool steels due to its high temperature strength, toughness and resistance to grain growth.

Overview
Tungsten hot-work steels constitute the H21 to H26 types of hot work steels. These steels have similar characteristics as those of other of high-speed steels. The hot work steel type H26 has low carbon content when compared to that of T1 high speed steel. The primary alloying elements of tungsten hot-work steels include tungsten, carbon, chromium and vanadium.

Properties
Tungsten hot work steels have high alloy content, which enhances their heat resistance. The high alloy content also makes the tungsten steels brittle and unsuitable for the water-cooling process. Breakage of tungsten hot work steels can be reduced if they are preheated to operating temperatures prior to use. Tungsten steels have normal working hardness of 45 to 55 HRC. Thermal shock resistance and toughness of these steels can be improved by reducing the carbon content. In such cases, it is necessary to adjust the tungsten and vanadium content also as these two reduce the hardenability of steel by trapping large amount of carbon in the form of carbides.

Scaling can be reduced by quenching tungsten hot-work steels in oil or hot salt. Tungsten hot-work steels are resistant to distortion when they are air- hardened, and have higher hardening temperature when compared to chromium hot-work steels.

Applications
Tungsten hot work steels find applications in the following areas:

•Manufacturing mandrels and extrusion dies for high temperature applications, such as extrusion of brass, nickel alloys, and steel
•Hot-forging dies of rugged design.

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Background
200 million tungsten bullets a year, using an ounce of tungsten each. That makes more than 5,500 t, or one eighth of existing annual tungsten consumption in the world.
 
Green Bullets
In 1999 the US Army began manufacturing "green" bullets. The bullets - which are used primarily for shooting practice during peace time - are as deadly to humans as their predecessors but less deadly to the Earth.

Lead bullets, which the Army currently uses, tend to bioaccumulate in the environment, often ending up in sediments, surface water, and groundwater, according to A Multimedia Strategy for the Management and Reduction of Lead Hazards released by the US Environmental Protection Agency Region 5. Accumulated lead can adversely affect wildlife and people who get their drinking water from a contaminated source, according to the report. Lead slugs are such a water quality hazard that the federal district court in New York ruled that spent lead shot is a "pollutant" as defined by the Clean Water Act.

The lead slugs the Army uses in traditional 5.56 mm bullets have been bioaccumulating at shooting ranges, forcing several to close. These slugs will be replaced with environmentally friendly tungsten-based slugs, according to Wade Bunting, project manager for environmental armament technologies at the Picatinny Arsenal in New Jersey. Not only is tungsten more environmentally "benign" than lead, but ozone depleting chemicals and volatile organic compounds have been eliminated from the bullet manufacturing process - resulting in pollution prevention and money savings, he says. Although tungsten is more expensive than lead, the cleanup of the manufacturing process actually will result in savings of $0.01 to $0.05 per round, or $5 million to $20 million per year, he explains.

The bullets also will allow several indoor and outdoor shooting ranges that closed because lead concentrations became a human health or environmental hazard to reopen, cutting down the costs of transporting troops to far away, still-operational shooting ranges and eliminating associated pollution he adds.

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