Tungsten Copper Wire Process

The basic process of tungsten copper wires is : Mixing → molding or isostatic pressing → infiltration, sintering tungsten copper rod or tungsten copper block → machining. Except conventional infiltration process, there are some popular processes used more, such as high-temperature liquid phase sintering and activated liquid-phase sintering. The principle of infiltration is that porous tungsten skeleton wetted by copper liquid, under the capillary force the copper liquid flows along the W particle gap, filling the pores of porous tungsten skeleton. So tungsten copper materials have higher density, excellent sintering properties and electrical conductivity; High temperature liquid phase sintering since the sintering temperature is high, a long time, will make a lot of volatile copper phase, so that the sintered tungsten copper material density decrease, the performance will be subject to different degrees of impact, it is difficult to obtain a high density, high conductivity tungsten copper alloy material; activated liquid phase sintering improves the relative density, the hardness and tensile strength of tungsten copper by adding small amounts of trace elements (Ni, Fe, Pd, etc.). But on the contrary, the activated elements will dramatically decrease the electrical and thermal conductivity, which is not suitable for the occasions with high requirements of the conductivity.

The technologies to machine tungsten copper rod or block in wires include drawing processing, rolling processing, roller die drawing techniques and rotary forging technology. Drawing processing take advantage of metal plasticity, when working in the external force so that it is forced through the die, the metal cross-sectional area is compressed to obtain the desired cross-sectional shape and size of the processing method. Preparation of tungsten and copper wire by repeatedly hammering and drawing forming, drawing conducted at room temperature, metal products will produce obvious hardening.

But for tungsten copper with lower Cu content, it has poor plasticity, the drawing rate received extremely limited, which is difficult to draw molding; rolling process is to rely on the friction two rotating rollers and the rolling member rolling pulled into the roll gap, it is compressed to produce plastic deformation process. In addition, the rolling process can also refine the grain, improve the organization, can significantly improve the mechanical properties of the metal alloy, suitable for mass production; Roller die drawing process the billet is drawn in a non-grooved drive, freely rotating rollers consisting of, the sliding friction with the material of the die orifice was changed to rolling friction bearing, the stretching process is more effort not only suitable for drawing round wire, shaped wire may be stretched, but not suitable for low plastic material.

Tungsten Copper Wire Description

Tungsten copper alloy is a kind of psudoalloy, which consists of the hard phase W and the binder phase Cu two immiscible metals, so it only can be fabricated by PM (Powder Metallurgy). Tungsten copper material has both advantages of tungsten and copper, the high density, high melting point, excellent wear resistance and corrosion resistance of W; the excellent electrical and thermal conductivity, good plasticity of Cu; and at a temperature above the melting point of copper alloy of copper liquefied evaporated to absorb a lot of heat, reducing the surface temperature. So tungsten copper material is also known as heat sink materials.

According to the shapes and applications, tungsten copper products can be specifically divided into tungsten copper rod, tungsten copper block, tungsten copper plate, tungsten copper contact, tungsten copper tube, tungsten copper electrode, tungsten copper heat sink, tungsten copper wire and so on. In the early 1960s, tungsten copper wire and tungsten copper electrode has been used in EDM (Electrical Discharge Machining) and resistance welding because of its high density, high strength, excellent electrical and thermal conductivity and arc ablation resistance. So far, with the developments of relevant technologies and further study of researchers, tungsten copper begin to use in plasma electrode material processing, precision machining, spraying, LED and other electrode fields. But since the special PM structure of tungsten copper, it has been greatly limited used in wire. In order to improve the uniformity, mechanical properties and production cost, it needs to looking for new technologies and processes.

Used in EDM electrodes of tungsten copper wires are supposed to meet the following requirements:
1. On the basis of excellent electrical and thermal conductivity, it also has good resistance to spark erosion;
2. Good structure uniformity and density, in order to ensure the stability of the electrical processing and improve the utilization of electrode material;
3. It has lower machining consumption and dose not affects the quality and the overall efficiency;
4. Easy for molding, machining molds and products according to design requirements to provide a correspondingly shaped profile tungsten copper electrode bars or complex shapes.

tungsten copper wire

 

Titanium Based Tungsten Trioxide Denitration Catalyst

different types of SCR catalystsTitanium is a silvery-white transition metal, which is considered as a rare metal, with the properties of light-weight, high-strength, metallic luster, moisture chlorine corrosion; its most common compound is titanium dioxide, which is often used as the carrier of denitration catalyst. The typical plate denitration catalyst is based on stainless steel and coated with a catalyst paste (ingredients: titanium dioxide, vanadium pentoxide, tungsten trioxide and molybdenum trioxide, etc.).
 
Because of tungsten, molybdenum, vanadium and other metals and their compounds are usually expensive, for seeking a higher cost-effective, the researchers decided to start with the substrate of plate tungsten trioxide denitration catalyst to improve its property. Experiment has shown that metal titanium or its alloy can meet their demands. Compared to stainless steel, the titanium has a higher strength / weight ratio because of its light-weight, high-strength; when used as the catalyst substrate, it can cut off 1/2 of the weight with the remaining high strength, and loading the same amount of active substance while significantly reducing the weight of the SCR denitration system. Furthermore, since titanium also purchases according to the unit weight, which is to say the cost of the titanium substrate is approximately equal to that of the stainless steel substrate.
 
In addition, titanium based of tungsten trioxide plate denitration catalyst due to the choice of titanium plate with through-hole which makes the whole SCR system able of rapid heating and cooling, and quickly response to the changing conditions. Insiders know the most efficient temperature range of NOx removal reaction is very high and narrow; however, the titanium substrate can exactly effectively overcome this disadvantage. Also, if the catalyst is cracking or chipping, the exposed titanium will be oxidized to titanium dioxide by the oxygen in the high temperature of exhaust gas, which also contributes to the catalytic denitrification.

 

Tungsten Trioxide Contained Vehicle Denitration Catalyst without Vanadium

The main pollutants in vehicle emissions are hydrocarbons, nitrogen oxides, carbon monoxide and particulate and so on. SCR is the known way with best denitration effect, while the core technology of it is SCR denitration catalyst. Earlier, the denitration catalyst is mainly based on automobile platinum, gold and other precious metal, and later began to use non-precious metal oxide as the main active ingredient. Selective catalytic reduction using ammonia or compound which can decompose into ammonia is the public known way for removing nitrogen oxides from the exhaust gases of lean burn internal combustion engine, which contains active ingredients like titanium dioxide, tungsten trioxide, vanadium pentoxide.
automobile exhaust gas denitration apparatus
However, when SCR catalyst containing vanadium used for cleaning motor vehicle exhaust, it may lead to toxic vanadium compound going into the air because of the volatility of vanadium under high temperature, thus to cause environmental pollution and personal injury. So, the listed capacity of the car catalyst containing vanadium is low. Therefore, for a long time, researchers and vendors are ongoing committed to provide no vanadium SCR denitration catalyst.
 
Rare earth with the reputation of industrial "vitamins" and "gold" has become an extremely important strategic resource consistent with the metal tungsten. Research indicated that the incorporation of rare earth oxide catalyst can effectively replace the vanadium based catalyst, which exhibits excellent performance. Studies have indicated that some catalyst doping into cerium-zirconium mixed oxide, and also the sulfur, molybdenum, tungsten (in form of tungsten trioxide) compound; in which the ingredients are: 0.02~3% of cerium-zirconium mixed oxide, 5~15%, 0.5~3% of tungsten trioxide (or molybdenum trioxide). This kind of SCR catalyst uses a ceramic flow-through monolith honeycomb wall flow type filter or a ceramic matrix, is particularly suitable for lean burn internal combustion engine exhaust gases to remove nitrogen oxides with the properties of highly activity and anti-aging.

 

Testing Standards of Carbon Sulfur Analyzer and Tungsten Granule——Test Conditions and Test Methods

Except the technical requirements, testing standards of carbon sulfur analyzer and tungsten granule also include - test conditions, test methods, management of the results of treatment, re-testing period. The relative standard deviation of carbon is lower than 1.0%, sulfur should be lower than 4.0%, the analysis time should less than one minute, the weighing stability of less than 0.002 grams. Environment conditions for testing should meet the standards. The ambient temperature should be controlled between 15 ℃ to 30 ℃, relative humidity must be less than 80%. If it is measured against the amount of 0.0010% to 0.0100% of the carbon and sulfur, the relative humidity should be less than 60%. Power supply is (220 ± 4.4) V, (50 ± 1) Hz, and it should be ensured that the detection environment has no strong vibration, no strong electric, no active gases and without any impede of magnetic fields.

The main test equipments and materials for detection should be in accordance with national standards. Using the approved the steel components by the state metrological administrative department to analyze national primary, secondary reference material. Uncertainty of the determination of carbon and sulfur less than one-third of error of indication, weighing with 1g standard weights. According to visual indication and touch to detect the appearance of instrument. The instrument is required to be preheated on the basis of instructions before detecting. Select carbon content within the range from 0.100%  1.000%, and choose sulfur content within the range from the 0.010% to 0.100%, weighing 0.5 g of sample every time, repeated detecting for 7 times, calculating the standard deviation and relative standard deviation in according with the standard formula calculation method . Weighing with 1 g standard weight, continuously weighing for six times, the difference between the maximum and the minimum is called weighing stability. After the test is completed, certificate of qualification can be sent, if unqualified, pointing out that the failed project. Test cycle usually two years. While moving, repairing or doubting on the measurement results, users can test the instrument.

If the carbon sulfur analyzer used by the company are not included in the mandatory verification of measuring instruments catalog, on the other hand, these instrument are not applied in trade settlement, safety, health, environmental monitoring, there is no need to test it compulsively.

carbon sulfur analyzer and tungsten granule

 

 

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