Ultrafine Grain Tungsten Heavy Alloys with Excellent Performance Prepared by Spark Plasma Sintering

Ultrafine grain tungsten heavy alloys (WHAs) were successfully produced from the nano-crystalline powders using spark plasma sintering.The present study mainly discussed the effects of sintering temperature on the density,microstructure and mechanical properties of the alloys.The relative density of 98.12% was obtained at 1 050 ℃,and the tungsten grain size is about 871 nm.At 1 000 ℃-1 200 ℃,the mechanical properties of the alloys tend to first rise and then goes down.After SPS,the alloy exhibits improved hardness (84.3 HRA at 1 050 ℃) and bending strength (987.16 MPa at 1 100 ℃),due to the ultrafine-grained microstructure.The fracture mode after bending tests is mainly characterized as intergranular or intragranular fracture of W grains,interfacial debonding of W grains-binding phase and ductile tearing of binding phase.The EDS analysis reveals a certain proportion of solid solution between W and Ni-Fe binding phase.The good mechanical properties of the alloys can be attributed to grain refinement and solid solution strengthening.

Ultrashort-time liquid phase sintering of high-performance fine-grain tungsten heavy alloys by laser additive manufacturing

Liquid phase sintering(LPS)is a proven technique for preparing large-size tungsten heavy alloys(WHAs).However,for densification,this processing requires that the matrix of WHAs keeps melting for a long time,which simultaneously causes W grain coarsening that degenerates the performance.This work develops a novel ultrashort-time LPS method to form bulk high-performance fine-grain WHAs based on the principle of laser additive manufacturing(LAM).During LAM,the high-entropy alloy matrix(Al_(0.5)Cr_(0.9)FeNi_(2.5)V_(0.2))and W powders were fed simultaneously but only the matrix was melted by laser and most W particles remained solid,and the melted matrix rapidly solidified with laser moving away,producing an ultrashort-time LPS processing in the melt pool,i.e.,laser ultrashort-time liquid phase sintering(LULPS).The extreme short dwell time in liquid(-1/10,000 of conventional LPS)can effectively suppress W grain growth,obtaining a small size of 1/3 of the size in LPS WHAs.Meanwhile,strong convection in the melt pool of LULPS enables a nearly full densification in such a short sintering time.Compared with LPS WHAs,the LULPS fine-grain WHAs present a 42%higher yield strength,as well as an enhanced susceptibility to adiabatic shear banding(ASB)that is important for strong armor-piercing capability,indicating that LULPS can be a promising pathway for forming high-performance WHAs that surpass those prepared by conventional LPS.

Adiabatic shear banding of hot-extruded tungsten heavy alloy under cryogenic temperature

The effect of cryogenic temperature on adiabatic shear banding (ASBing) of tungsten heavy alloy (WHA) processed by hot-hydrostatic ex-trusion was investigated.Results show that,when the initial temperature is decreased,the dynamic flow stress,the critical failure time,and the dynamic failure energy of specimens show an increasing tendency,while the susceptibility to ASB of WHA shows a decreasing tendency,which is characterized by decreased shear strain and increased width of shear bands.Microstructure analysis shows that the number of mi-crocracks within ASB exhibits an increasing tendency with decreased initial temperature,and the dynamic recrystallization (DRX) process within ASB is evidently suppressed at the lower temperature.As a result of the lower temperature,the motion and rearrangement of disloca-tion are effectively suppressed,which is mainly responsible for the incomplete DRX process within ASB and decreases susceptibility to ASB.

Application of the Backpropagation Neural Network Method in Designing Tungsten Heavy Alloy

The model describing the dependence of the mechanical properties on the chemical composition and as deformation techniques of tungsten heavy alloy is established by the method of improved the backpropagation neural network. The mechanical properties＇ parameters of tungsten alloy and deformation techniques for tungsten alloy are used as the inputs. The chemical composition and deformation amount of tungsten alloy are used as the outputs. Then they are used for training the neural network. At the same time, the optimal number of the hidden neurons is obtained through the experiential equations, and the varied step learning method is adopted to ensure the stability of the training process. According to the requirements for mechanical properties, the chemical composition and the deformation condition for tungsten heavy alloy can be designed by this artificial neural network system.

Effect of microstructural parameters on the properties of W-Ni-Fe alloys

The aim of this research was to examine the effect of microstructural parameters on the tensile properties of different compositions of tungsten heavy alloys. The microstructural parameters （grain size, connectivity, contiguity, and solid volume fraction） were measured and were found to have a significant effect on the tensile properties of tungsten-based heavy alloys. The microstructural parameters of W-Ni-Fe alloys are sufficiently different to present a range of mechanical properties. It is concluded that the mechanical properties of tungsten heavy alloys largely depend on the microstructural parameters and their ductility is particularly harmed when grains are contiguous.

Ultrasonic-assisted soldering W90 Tungsten heavy alloy to AZ31B Mg alloy using Sn-x Al alloy

A double-layered W/Mg structure is expected to be a new generation of nuclear radiation shielding material.The tungsten heavy alloy(W90)and AZ31B Mg alloy were firstly bonded by ultrasonic-assisted soldering using pure Sn and Sn-Al filler metal in an atmospheric environment.The influence of ultrasonication time on the microstructure and mechanical properties of the joint was investigated.The typical microstructure of the W90/Sn/Mg joint was W90/Mg_(2)Sn+Sn/Mg_(2)Sn layer/Mg.As the ultrasonication time increased from 2 s to 10 s,the joint width reduced and the thickness of the Mg_(2)Sn layer increased.The shear strength of the joint firstly increased,then flattened,and finally decreased.The joint strength reached the maximum value of 10.5 MPa.The fracture position of the joint changed from the W90/filler metal interface to the Mg_(2)Sn layer.The addition of Al in Sn resulted in the formation of the Al4 W phase at the W/Sn-1Al interface.The W/filler metal interface changed from the semi-coherent interface to the coherent interface and the joint strength increased.As the ultrasonication time was 6 s,the shear strength W90/Sn-1Al/Mg joint reached the maximum value of 24.6 MPa and the joint fractured at two positions:W90/filler metal interface and filler metal.With the further increase of ultrasonication time,the joint strength decreased and the joint fractured in the Mg_(2)Sn layer.

Aging Behaviors of W-Ni-Fe Ternary Alloys with High Ni-to-Fe Ratios

The hardness variation of two kinds of alloys with 36 wt pct W content and 7/3, 9/1 Ni-to-Fe ratios during strain aging at 800℃ was studied. The microstructures of the aged alloys were analyzed by X-ray diffraction and TEM. The results show that the strain aging hardness of W-Ni-Fe ternary alloy with 7/3 Ni-to-Fe ratio decreases monotonically with the increase of aging time. Under the same conditions, the hardness of 9/1 Ni-to-Fe ratio alloy decreases in the initial aging stage, but then increases as aging process goes on. X ray diffraction and TEM analysis show that there is not any precipitation depositing from the alloy with 7/3 Ni-to-Fe ratio during aging. The monotonic decrease in hardness of this alloy during aging process results from the recovery, recrystallization and solid solubility declining. In the alloy of 9/1 Ni-to-Fe ratio, the fine β phase precipitates dispersively during aging which hardens the alloy. The two different kinds of mechanisms (the softening one and the hardening one) decide the hardness variation of the alloy with 9/1 Ni-to-Fe ratio mentioned above.

Experimental study on WFeNiMo high-entropy alloy projectile penetrating semi-infinite steel target

The appearance of high-entropy alloys (HEAs) makes it possible for a material to possess both high strength and high ductility. It is with great potential to apply HEAs under extreme conditions such as in the penetration process. In this paper, experiments of WFeNiMo HEA and tungsten heavy alloy (WHA) projectiles penetrating medium-carbon steel were conducted by using the ballistic gun and two-stage light-gas gun that can accelerate projectiles to impact velocities ranging from 1162 m/s to 2130 m/s. Depth of penetration (DOP) at elevated impact velocities of HEA and WHA projectiles were obtained firstly. Combined with the macroscopic and microscopic analysis of the residual projectiles, the transition of the penetration mode of the WFeNiMo HEA projectile was identified systemically. The experimental results indicated that the penetration mode of the HEA projectile changes from self-sharpening to mushrooming with the increase of impact velocity, while for the WHA projectile, the penetration mode is always mushrooming. The microstructure of the residual HEA projectiles showed that the phases tangle with each other and the morphology of the microstructure of the phases differs in the two penetration modes. Besides, the evolution of shear bands and fractures varies in the two modes. The evolution of the microstructure of HEAs causes the sharp-pointed nose to disappear and the HEA projectile ultimately becomes blunt as the impact velocity increases.

Morphology and microstructure characterization of 95W-3.5Ni-1.5Fe powder prepared by mechanical alloying

The mechanism of mechanical solid-state reactions for formation of tungsten heavy alloy powder was discussed. A highenergy ball mill operating at room temperature was used for preparing tungsten heavy alloy powders, starting from elemental tungsten （W）, nickel （Ni）, and iron （Fe） powders. X-ray diffraction （XRD）, particle size analyzer, scanning electron microscopy （SEM）, and transmission electron microscopy （TEM） were used to follow the progress of the mechanical solid-state reaction of W, Ni, and Fe powders. These morphological studies revealed three stages in the milling process. In the first stage, the particle deformation changes the irregular structure of the as-received powder particles to flattened morphology, and the average particle size increases. In the second stage, the powder is sufficiently deformed and the tendency to fracture predominates over welding, and the particle size decreases. With continuous milling, the system reaches steady state, and relatively small and uniform particle size distribution is obtained after 20 h of milling.

Mechanical properties of tungsten heavy alloy and damage behaviors after hypervelocity impact

93W-4.5Ni-l.5Fe-lCo （W） was prepared by powder metallurgic method, and then dynamic mechanical properties of this material were tested at high temperature by means of high-temperature split Hopkinson pressure bar （SHPB）. The results show that the material possesses high- dynamic mechanical properties, significant temperature effects, and strain hardening behaviors. Used two-stage light gas gun, the penetration test of 93W projectile was finished. After the completion of the test, through the microstructure observation of the residual 93W projectiles with the aid of scanning electron microscopy （SEM） and transmission electron microscopy （TEM）, it can be found that there are obvious signs of hot melt existing on the surface of the projectile, a lot of adiabatic shear bands inside the projectile, and microcracks exist at the end of adiabatic shear bands. The test results show that adiabatic shear is the main form to cause the projectile failure and it is the emergence of the adiabatic shearing phenomenon that makes 93W display good self-sharpening property in the process of hypervelocity penetration. At the same time, the results of TEM observation show that there are high- density dislocations at the interface between W and Ni-Fe- Co-based alloy inside the 93W.

Prediction and optimization of machining forces using oxley’s predictive theory and RSM approach during machining of WHAs

Tungsten heavy alloys have come up as one of the best alternatives for high density fragmenting devices and armor piercing ammunition.Machining is mandatory for obtaining the final shapes of such kind of ammunitions.However,due to high density and elastic stiffness of WHAs,cutting forces will be higher than for most of the metals and alloys;thus,making the machining operation challenging.The machining variable,namely,cutting force components are significantly influenced by the cutting parameters.This paper makes use of Oxley’s predictive analytical model in conjunction with Johnson-Cook constitutive equation to predict forces under different speed and feed combinations during machining of 95 W tungsten heavy alloy.The cutting forces,so predicted by Ml,are considered as input data for the optimization of cutting parameters(cutting speed and feed)using Response Surface Method(RSM).

Design of ultrasonic elliptical vibration cutting system for tungsten heavy alloy

Nanoscale surface roughness of tungsten heavy alloy components is required in the nuclear industry and precision instruments.In this study,a high-performance ultrasonic elliptical vibration cutting(UEVC)system is developed to solve the precision machining problem of tungsten heavy alloy.A new design method of stepped bending vibration horn based on Timoshenko’s theory is first proposed,and its design process is greatly simplified.The arrangement and working principle of piezoelectric transducers on the ultrasonic vibrator using the fifth resonant mode of bending are analyzed to realize the dual-bending vibration modes.A cutting tool is installed at the end of the ultrasonic vibration unit to output the ultrasonic elliptical vibration locus,which is verified by finite element method.The vibration unit can display different three-degree-of-freedom(3-DOF)UEVC characteristics by adjusting the corresponding position of the unit and workpiece.A dual-channel ultrasonic power supply is developed to excite the ultrasonic vibration unit,which makes the UEVC system present the resonant frequency of 41 kHz and the maximum amplitude of 14.2μm.Different microtopography and surface roughness are obtained by the cutting experiments of tungsten heavy alloy hemispherical workpiece with the UEVC system,which validates the proposed design’s technical capability and provides optimization basis for further improving the machining quality of the curved surface components of tungsten heavy alloy.

Microstructure and mechanical properties of spark plasma-sintered La_(2)O_(3) dispersion-strengthened W-Ni-Fe alloy

An investigation of lanthanum oxide(La_(2)O_(3))addition to tungsten heavy alloy(WHA)with a ternary composition of W-7 Ni-3 Fe was reported in this study.The mixed powders were sintered using spark plasma sintering(SPS)technique.La_(2)O_(3)was added in increments of 0.25 wt%,0.50 wt%,0.75 wt%and 1.00 wt%to WHA,respectively.The sintered samples were characterized for microstructural evolution and mechanical properties.The influences of La_(2)O_(3)addition on density,grain size,hardness,ultimate tensile strength(UTS)and ductility on W-7 Ni-3 Fe system were discussed in this study.The highest relative sintered density of 87.95%was obtained for 0.25 wt%La_(2)O_(3)addition to W-7 Ni-3 Fe.The lowest grain size of 7.89μm was observed for 1.00 wt%La_(2)O_(3)addition.Similarly,the highest hardness and UTS of HV 533 and1110 MPa,respectively,were also obtained for the same composition.Scanning electron microscopy(SEM)and energy-dispersive spectroscopy(EDS)of the samples revealed homogenous distribution of La_(2)O_(3)in the alloy matrix.Fractography of the sintered alloy samples revealed W-W intergranular fracture.