Tungsten Copper Sheet Sintering Process

Tungsten copper materials perfectly combine high hardness, high melting point, high strength, low coefficient of thermal expansion and excellent wear and corrosion resistance of W with high plasticity and excellent thermal and electrical conductivity of Cu. Furthermore, it has another advantage that other material difficult to achieve: there is a great difference in the melting point between W and Cu (W-3380℃, Cu-1083℃), at a temperature exceeding the melting point of Cu, copper evaporation can take away the most of heat and keep the matrix working normal. So it is also called sweating heat sink material.

With the development of electronic devices now tend to be miniaturized and high-power, heating and cooling is an inevitable process of the devices. Tungsten copper alloy with superior performance to meet the cooling requirements of high-power devices, and it may also adjust the coefficient of thermal expansion, and microelectronics devices of different semiconductor materials are well matched connection, so as to effectively prevent heat stress thermal fatigue damage caused. Therefore, in some LSI (large-scale integrated circuit) and high-power microwave devices, tungsten copper sheet has a broad prospect in electronic packaging substrates, heat sinks, connectors and other microelectronic housing material.

tungsten copper sheet

Theoretically, as heat sink material, tungsten copper sheet has a strict requirement of theoretical density, usually higher than 98% and the thickness less than 1mm, which conventional PM (powder metallurgy) is difficult to meet the increasing requirements. Recent years, the relevant researchers and scholars have studied in ultra-fine powder fabrication, densified process and alloy molding technology. For tungsten copper sheet sintering process, Surface wettability of densification, microstructure and properties of the alloy a great impact, and tungsten copper two-phase sintering temperature depends on the wettability of tungsten and copper two phases. Through the experiment can be found that sintered at 1200 ℃, tungsten particles agglomerate, with copper and tungsten particles did not enter the group, there are many small voids between the particles of tungsten and copper group phase, which indicates Cu has poor wettability at this time; when sintering temperature up to 1300℃, the wettability of Cu has improved, so it can immersed in the tungsten particles, which is beneficial for flowability and rearrangement of W grains. With the increase of sintering temperature, then Cu phase occurs gathering, that is copper pool of depression phenomenon, inter tungsten particles re-agglomerate and grow interconnected to provide the conditions so that the density of tungsten copper alloy in high temperature sintering stage quickly increase.

Tungsten Bar and Doping Bubble

wolfram barIn the early 1900s, the United States developed a high temperature anti-drooping tungsten wire. Doping (semiconductor), intentionally introducing impurities into an extremely pure semiconductor to change its electrical properties. After many tests, it is found that its sagging resistance is due to a small amount of silicon, aluminum, potassium oxide in the tungsten oxide before reduction. Among them, the researchers proposed a "bubble statement." "Bubble statement" holds the view that the dopant is prone to have the doping effect in the first reduction process, and then form the doping bubble during the vertical melting. These bubbles will be stretched, annealed in follow-up processes. Then it will become small holes arranged in clusters, but these holes may have an impact on the cross motion of tungsten filament grain boundaries during the second recrystallization, or even hinder its movement, eventually leading to the tungsten wire forming a especial recrystallized grain structure, which would make wolfram filament have a high temperature sagging resistance.  Anti-sagging tungsten filament is mainly used for incandescent, fluorescent and other light bulb and the heat wire of tube. Anti-sagging tungsten wire of automobile and motorcycle lights is one of the most important applications. There are many methods to detect its anti-sagging performance, the most common ways include high-temperature creep test, high temperature bending drop method (V-shaped test), etc.

Through the preliminary calculation of the test, it can be concluded that the effective conductive cross section area of tungsten bar would significantly reduced if content of potassium increasingly. Because residual potassium will evaporate into gas in a sintering process, and then produce large amounts of adulterate bubble, resulting in a reduction of its effective conducting cross-sectional area. When potassium content is lower than 70ppm, change of density of adulterate bubbles is more pronounced, it would reduced rapidly as decreasing of potassium content, which will reduce the high temperature sagging resistance of tungsten filament.

When Formaldehyde Meets Tungsten Trioxide Photocatalyst

Formaldehyde (https://zh.wikipedia.org/wiki/%E7%94%B2%E9%86%9B) is the gas of colorless and sensory irritant effects, its main harm is done to the skin mucous membrane irritation, when the content of formaldehyde in room reaches to a certain concentration, people will feel a sense of discomfort. When the concentration of formaldehyde is greater than 0.08 mg/m³, it will cause eye irritation, throat discomfort or pain, chest tightness, asthma, dermatitis, and so on; in addition, it has the bad influences like mutagenicity, carcinogenicity. In the year of 2011, the National Toxicology Program of United States described formaldehyde as the "known human carcinogen".photocatalyst removes formaldehyde
 
Moreover, the decoration board, paint furniture and automotive accessories and decorative objects, etc., which carry the harmful gases of formaldehyde can cause all kinds of chronic respiratory diseases. In foreign, people have very strict standard on the formaldehyde content controlling. Recently, an export of wood products in Taizhou, Zhejiang is sent back by the foreign for the first time, because of the content of formaldehyde and volatile substances is beyond the standard. We say, if they would spary the tungsten trioxide photocatalyst coating on the surface of building materials or formaldehyde-containing substrate, such a problem should not occur. Of course, the manufacturer cutting off the source of formaldehyde pollution is the key.
 
The principle that photocatalyst removes formaldehyde from building materials is: when exposure to ultraviolet light, the hydroxyl ions on the surface of photocatalyst will be oxidized to the hole "hydroxyl radical" by the electronic holes, the hydroxyl radicals will grab electrons from other organic compounds (formaldehyde and various of volatile organic compounds), and the organic compounds which are taken away electrons will be degraded into smaller molecules (such as carbon dioxide and water ect.) due to the loss of electronic bonding ability. Compare to the formaldehyde remover, the photocatalytic decomposition will not generate subsequent harmful organic compounds, thus to avoid a secondary pollution.
 
In addition, since tungsten trioxide photocatalyst has a wider optical response band of visible light, it can effectively take advantage of visible light and artificial lighting in indoor, no longer depend on the sun's ultraviolet rays, therefore, they can also play a very good decomposition effect of the formaldehyde in the internal of cupboard which can not often be irradiated by the bright light. Thus, the photocatalyst is considering as the most ideal material for removing formaldehyde, because its safety, small energy consumption, safe and harmless of the final product (carbon dioxide and water), etc..

 

Tungsten Bar - Indirect Heating Sintering

wolfram barTungsten bar can be used for the manufacturing process of tungsten filament. So far, most factories adopt vertical sintering method. Such method is working in a water cooling bell, but there is no equipment to keep warm in this bell. Then a large amount of thermal energy generated by electric power are used for heating water, but hot water need cooling device for cooling, this process will consume a lot of power. The temperature field gradient of this method is relatively large, resulting in the density, grain size and degree of porosity of the same batch of tungsten are different. What’s more, density of both ends of the billet is very low, so they must be removed, so that it would waste a part of resources.

To a certain degree indirect heating sintering method can solves these drawbacks, it also improve their quality of billet, which has an excellent energy saving effect. In 1976, an intermediate frequency (IF) induction sintering furnace had been already developed, this device will be able to meet the conditions of uniform temperature field for sintering the tungsten bar. It adopts a tungsten tube as a heating element, and jargonia is a heat insulating material. A sealing member consists of them, the heat energy generated by electrical energy will be surrounded by the sealing member, and concentrated in the middle of the furnace for sintering the wolfram bar.

Horizontal can keep consistent with vertical properties of the bars prepared by this method. In addition, this kind of bars would have a uniform and thin microstructure. The density of both sides of billet does not have a great difference with other parts, so they are not need to be removed. IF induction furnace indirectly heating tungsten products would ensure the stability of its quality, and the more important point is that it can save resources, which plays an important role in environmental protection.

Encounter Tungsten Trioxide Photocatalyst

The Twenty-first Century is said to be the era of the environment. One of the great features of photocatalyst is the using of solar energy and rain as the main energy without adding burden to the environment. Since the photocatalytic phenomenon has been found, is has been more than 40 years; and about 20 years ago, people discovered that after the mirror glass surface coated with titanium oxide post-treatment, the mirror will not be hazy any more. The reason is that under the bright light, a portion of the oxygen on the mirror surface is removed, so that the water is more easily absorbed, and get closer to the water, creating a flat surface of a water droplet formation, which is super-hydrophilic response.car rearview mirror coated photocatalyst
 
This super hydrophilic effect of photocatalyst is also used in car side rearview mirror. However, since the horizontal on the surface of the photocatalyst slip attached to the precarious situation, if it is placed in the dark situation, it will return to the original state of the surface of titanium oxide. However, if you use both silicon and photocatalyst to carry out a surface coating process, since the silicon is easy to store water, the complementary effects can be brought out.
 
Photocatalyst mainly used in four areas, which are air purification, automatic cleaning, water purification, and antibacterial, sterilization. For example, deodorizing means which uses photocatalytic technology is placed on the smoking plate; rely on the photocatalyst, the photocatalyst air purifier which is mounted on the ceiling can break down acetaldehyde and ammonia in the flue gas; besides, some of the station platform using the photocatalyst added tent; also the artificial flowers’ leaves after the photocatalyst surface coating process, can used for adsorption of smoke in the room air, and so on.
 
Tungsten trioxide is the found and the successful development and mass process, which is a visible light-type photocatalyst with more than 10 times of the conventional photocatalytic activity, it responses the wavelength range of light from 400nm to 800nm . This new type of photocatalyst is added copper ions into tungsten trioxide, electrons move from the tungsten oxide to copper ions during the reaction, copper ions will store electrons and produce an efficient reduction reaction. This high-performance of visible light-type of photocatalyst is believed to play the effects of air purification, pollution prevention, anti-bacterial, anti-viral and so on in indoor environment, moreover, it is expected to have further practical use.
 
With the successful development of high-performance type of visible light photocatalyst, tungsten oxide has been increasingly attended, especially the nano tungsten trioxide, which is the tungsten oxide with a large specific surface area, a significant effect, a special oxidation catalytic performance. As a wide band gap of the n-type semiconductor, nano tungsten oxide photocatalyst is placed very high expectations in the decomposition and elimination of air pollutants, volatile organic compounds (VOC) in indoor air, in addition, stench removal, preventing a worldwide prevalence of infectious diseases, etc..

 

 

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