Abstract
Tungsten heavy alloy powders were produced from freeze-dried aqueous solutions of ammonium metatungstate and, principally, sulfates of Ni and Fe. The freeze-dried salts were calcined and hydrogen reduced to form very fine, homogeneous, low-density, W heavy alloy powders having a coral-like structure with elements of approximately 0.1 /mu/m in diameter. The powders yield high green strength and sinterability. Tungsten heavy alloy powders of 70%, 90%, and 96% W were prepared by freeze drying, compacted, and solid-state (SS) sintered to fully density at temperatures as low as 1200/degree/C and also at conventional liquid-phase (LP) sintering temperatures. Solid-state sintered microstructures contained polygonal W grains with high contiguity; the matrix did not coat and separate the W grains to form low-contiguity, high-ductility structures. Liquid-phase sintered microstructures were very conventional in appearance, having W spheroids of low contiguity. All these materials were found to be brittle. High levels of residual S accompanied by segregation of the S to all the microstructural interfaces are principally responsible for the brittleness; problems with S could be eliminated by using Fe and Ni nitrates rather than the sulfates. 9 refs., 22 figs., 3 tabs.
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