Tungsten Copper Heat Sink — Hot Forging

Tungsten copper heat sink materials not only have high density, high strength, high melting point and excellent wear and corrosion resistance, but also have high heat resistance and perfect thermal and electrical conductivity. It is important that it has matching thermal and linear coefficient of expansion to the chip and ceramic, which has a broad prospect in RF (Radio Frequency), microwave, optical communications and some other high-power electronic components. But the common tungsten copper heat sink materials fabricated by PM after Cu infiltrated will unavoidably appear some pores and defects, which has a bad effect on the hermeticity of electronics packaging materials. Hot forging is a kind new process that organically combines PM and hot hammering, it heated after sintered preform and forged in a closed die cavity. It can not only reduce the cutting loss effectively, but also can promote the densification and improve the structure and properties.

From the point of view microstructure, after forging high temperature tungsten copper composite material no larger diameter of the copper-rich region and Cu phase distributes uniformly. At the same time between the tungsten particles combine more closely, product density has been increased dramatically. In addition, after twice after forging, microstructure changes tungsten-copper composite material is not obvious at this time shows the deformation resistance and forging pressure inside the sample is quite internal sample no longer produce significant deformation and dislocation. After hot forging, tungsten copper material inside the pores decrease, increase density, air tightness and physical performance improved significantly. Through ultrasonic scanning analysis, we can find that the sample without forging has many small pores inside and there is almost no white dot after forging. On the other hand, processing tungsten-copper material through the internal temperature after forging without causing cracks larger pores gradually shrink or even disappear, thereby increasing the density of tungsten copper material, tungsten copper microstructure uniformity is further improved.

tungsten copper heat sinks

 

Tungsten Copper Contact Used for SF6 Circuit Breaker

SF6 circuit breaker uses SF6 gas as dielectric medium. Compared with conventional air circuit breaker, it also belongs to air blast circuit breaker. But there are some differences, such as lower working pressure, in the process of blowing the arc, and gas is not discharged to the atmosphere, but in a closed loop system used. Due to the perfect insulation and interrupter properties of SF6 gas, SF6 circuit breaker has many advantages, such as good breaking ability, high voltage suitable for fracture, allow continuous breaking more frequently, small in noise, no security threat, small electro-mechanical wear and so on which is a king of “maintenance-free” circuit breaker with excellent performance and has been widely used in high-voltage circuit. As the voltage level of the SF6 circuit breakers imposed increasingly higher and higher, the requirements of physical and electrical performance is also increasing.

In general, SF6 circuit breakers should meet the design requirements that the hardness of contact > HRB 82, the density > 13g / cm3, the conductivity ≥ 50% IACS, and after a 20-time All-breaking capacity test, the contact surface burning amount should not exceed 3mm. Conventional ratio has two kinds of W-Cu40 and W-Cu 35, wherein the content of W should not be too high (≤70%), otherwise the burning rate will increase. First of all, choose fine W powder is beneficial for reducing the burning rate, but too fine W powder will make liquid copper difficult infiltrate and easily form crumb defects on the matrix. Adding sintering additives will remarkably decrease the electrical conductivity and the burning loss has an increasing trend on the surface of contacts after cut-off. In addition, the granularity composition also needs a proper mixing ratio; viewed from the manufacturing process, add proper amount of induced Cu powder when mixing; leave some place for re-press when compacting; the volume of liquid copper must be equal to tungsten skeleton pore volume during sintering infiltration and it should be surface cleaned after cooling.

tungsten copper contacts

 

Tungsten Powder and Bronze Composite Material

Lead has been used in a variety of industrial applications for many thousands of years. In the last hundred years, the toxic effects of lead have become apparent. In an effort to reduce reliance on lead, there has recently been extensive research into materials that could be used to replace lead.
 
In this regard, much effort has been focussed on producing metal composites that mimic the properties of lead. Since the density of lead is the most obvious characteristic to mimic, most efforts have concentrated on finding composites that have the same or similar density as lead. However, other important properties of lead have been largely ignored and, as a result, no completely satisfactory lead replacement has yet been found.
 
In addition to being non-toxic and to having a similar density to lead, a successful composite should have reasonable softness coupled with structural rigidity. Ideally the composite is substantially homogeneous and relatively cheap to manufacture in large quantities.
 
tungsten powdertungsten powder
 
There still remains a need for a composite materials having a suitably high density, suitable processing characteristics and suitable properties for a variety of applications.
 
There is provided a composite comprising tungsten and bronze.
There is also provided a composite consisting essentially of tungsten, bronze, and iron.
There is also provided a process for producing a composite, the process comprising: blending powdered tungsten, powdered bronze, and an organic binder, thereby forming a homogeneous mixture; compounding the mixture at elevated temperature; and, cooling the mixture to form a composite having consistent characteristics throughout the composite.
 
There is also provided a process for producing an article comprising: providing a mold having an open ended cavity; placing a quantity of a homogeneous mixture of powders comprising tungsten and bronze in the cavity; placing a quantity of a powdered infiltrant on the mixture of powders in the cavity; sintering the mixture of tungsten and bronze powders at a first temperature followed by melting the infiltrant at a second temperature; and, cooling the mold and the articles formed therein.
 
Tungsten is generally used in the form of tungsten powder of polygonal shape and may be milled to the desired shape and mean particle size. The mean particle size is preferably about 0.5–50 μm, more preferably about 1–20 μm.
Bronze is typically an alloy of copper and tin. The ratio of copper to tin may vary depending on the particular alloy and the desired proportions of copper to tin in the composite. Most industrially useful compositions have a tin content of under 25% by weight. Many other additions at various levels are commonly used to alter the properties of bronzes. These may include but are not limited to metals and non-metals such as zinc, iron, manganese, magnesium, aluminium, phosphorus, silicon, lithium compounds, etc. Preferably, bronze having a Cu:Sn ratio of about 9:1 is used, this includes bronze having a Cu:Sn ratio of 89:11. Bronze is preferably used in the form of a powder and may be milled to the desired shape and mean particle size. The mean particle size is preferably under 100 μm, more preferably under 50 μm.
Generally, the density of the composite can be adjusted at will by varying the ratio of tungsten (density=19.3 g/cc) and bronze (density=8.9 g/cc for a 90:10 alloy of Cu:Sn). 
 
It was found that a composite comprising 40–85% tungsten by weight of the composite, the balance being bronze comprising 80–95% copper and 5–20% tin by weight of the bronze, was effective at producing a composite suitable for use as a lead replacement. Preferably, the composite comprises 50 to 55% tungsten, even more preferably 52% tungsten by weight of the composite and the bronze comprises copper and tin in a ratio of about 9:1 by weight of the bronze.
 
Tungsten particles offer resistance to densification during compaction as well as sintering. These issues may place an upper limit on the useful fraction of tungsten. The latter issue can also be partially offset by using finer tungsten grains.
The use of bronze in the formation of tungsten composites offers significant advantages over composite materials that have previously been described in the art, including the three component systems described in U.S. Pat. No. 5,950,064. Surprisingly, it has been found that suspensions of tungsten in bronze are more homogeneous and denser than suspensions of tungsten in other materials, particularly other metallic materials. The more even distribution of tungsten in the bronze matrix leads to superior and more consistent composite properties, such as higher impact strength and greater density. The use of tungsten in bronze also permits the use of a wider range of processing characteristics than the use of a three component system, such as those described in U.S. Pat. No. 5,950,064. When processing a three component system involving separate powders of tungsten, copper and tin, molten tin will dissolve into the copper matrix leaving non-removable voids or porosity, permitting aggregation of the tungsten particles that were next to the tin particles. As a result, the composite formed from the three component system is less homogeneous and of lower density than one formed from tungsten and bronze.
 
Other processing aids may be used during the production of tungsten/bronze composites, such as lubricants (for example, organic polymers, waxes, molybdenum disulphide, calcium difluoride, ethylene-bis-stearamide, lithium stearate, lithium carbonate, copper stearate, copper oleate, copper amines, and graphite), surfactants (for example, stearic acid) mould releasing agents (for example, zinc stearate) and wetting agents (for example, aluminum and basic polymers such as polyvinyl pyrrolidone).
 
tungsten powdertungsten powder

Tungsten Electrode Product Catalogue

Rare earth tungsten electrode with pink color, is radiation-free and can be alternative to WT20. The composition is tunsgten and raw earths. It combines the characteristics of all tungsten electrodes and allows you to reduce your range to one single type. It has outstanding ignitability, durability and arc quality and other advantages. It not only can usable for AC welding / aluminium, but also can apply in automatic & robot and manual welding. Packed by 10 pieces in a box.
 
Tungsten ceriated electrode (WC 20) with grey color, is the classic electrode for DC welding and the composition is W with 2% cerium. Due to its most advantage of outstanding durability and small drawbacks have to be accepted regarding iginitability, the WL15 and WT20 is the most popular electrode. Packed by 10 pieces in a box.
 
Tungsten lanthanated electrode (WL 10) with black color, is the favourite for plasma welding and cutting. And the composition is W with 1% Lanthane. It is most pertinent for its well ignitability. Besides, the field of main application is plasma welding and cutting. Packed by 10 pieces in a box.
 
Tungsten lanthanated electrode (WL 15 ) with gold color, it’s talent in all application areas. And its composition is W and 1,5% Lanthane. Besides, it is a real alternative to WT20.Compared with WL10, WL15 has higher lanthane content so the effects of ignitability is better. Packed by 10 pieces in a box.
 
Tungsten lanthanated electrode (WL 20) with blue color, is unbeatable performance in automatic and robot welding. And its composition is W and 1,5% Lanthan. The electrode with the highest lanthane content ensures unsupassed ignitability. The Main field of application is automatic & robot welding. Packed by 10 pieces in a box .
 
Pure tungsten electrode, its composition is pure tungsten. A classic electrode with middle welding characteristics and different alternatives to improve ignitability, durability and ampercity. Packed by 10 pieces in a box.
 
Tungsten zirconiated electrode (WZ 8) with white color, it is the specialist for aluminium. And the composition of it is W and 0.8% zirkon. WZ8 can improved ignitability, durability and ampercity compared to W green electrode. Packed by 10 pieces in a box.
 
Tungsten rhenium electrode (WR 2) with turkis color, is the 'cult' electrode. The composition is W with rare 2% rhenium. The saturated market with highly productive electrodes inevitably dooms this type to marginalisation. Packed by 10 pieces in a box.
 
Tungsten thoriated electrode (WT20) with red color, it is the most popular tunsgten electrode and widely used in many field. Packed by 10 pieces in a box.
tungsten electrode product catalogue

Deep Cryogenic Treatment Effect on Tungsten Carbide Materials

First of all, viewed from micro structure, deep cryogenic treatment has no obvious effect on the WC granularity, contiguity, and γ phase mean free path of tungsten carbide materials. Carbide without cryogenic treatment contains only a small amount of brittle η phases, by comparison, after the cryogenic treatment due to carbide long-term exposure to extreme temperatures and η phase increases. There are some experiments found that after deep cryogenic treatment, tungsten carbide has more uniform distribution, the binder Co and hard phase WC combined firmer and the overall wear resistance is significantly improved. Furthermore, the deep cryogenic treatment temperature provides greater two-phase free energy difference (High-temperature phase α-Co (fcc structure) and Low temperature phase Σ-Co (hcp structure)). At such low temperature, the atomic diffusion capacity reduced and formed no-diffusion phase transition process. In the research of deep cryogenic treatment of TW carbide inserts, we can found that the blade without deep cryogenic treatment has both of Σ-Co phase andα-Co phase, while the blade after treatment only hasΣ-Co phase. It indicates that after deep cryogenic treatment, Co of TW has a complete martensitic transformation. Overall, deep cryogenic treatment can promote binder Co transfer fcc structure to hcp structure.

Due to the great difference of the coefficient of thermal expansion and linear expansion coefficient between WC and Co phases of tungsten carbide, tungsten carbide has large thermal stress inside after cooling. And WC phase is subjected to compression stress, Co phase is subjected to tensile stress. By cryogenic treatment can make the carbide obtained two-phase thermal stress relaxation, thereby increasing the strength of carbide cutting tools. In addition, in mechanical properties, carbide cutting tools after deep cryogenic treatment, the hardness has greatly improved (from HRA90 to improve HRA92, HV1764 increased to HV2263.7). While YG6X, YG8, YG10C, YT14 four grades after deep cryogenic treatment, Various grades of alloy coercive force has been significantly improved, significantly lower than the saturation magnetization, has improved hardness, density substantially constant and flexural strength dramatically.

tungsten carbide mills

 

 

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