Hot-press Sintering Research Articles

Microstructure and properties of multiple hybrid reinforced CNTs-TiB2-TiC/Cu laminated composites

Cu matrix laminated composites reinforced with CNTs exhibit excellent mechanical properties; however, the Cu matrix between the laminated structures suffers from insufficient strength. To improve the strength of the matrix and the laminated structure in CNTs/Cu laminated composites, TiH2 and B4C particles were introduced into the Cu matrix via mixing powder, adsorption, hot-pressed sintering and cold rolling, furnishing CNTs-TiB2-TiC/Cu laminated composites. The tensile strength of the CNTs-TiB2-TiC/Cu laminated composites (513 MPa) increased by 26.04 % and 81.27 % compared with those of CNTs/Cu-Ti laminated composites (407 MPa) and CNTs/Cu laminated composites (283 MPa), and the elongation was 18.47 %. The in situ generated TiB2 and TiC reinforcement particles dispersed in the matrix materials induce particle strengthening, enhancing the dislocation density and load-bearing effect. Meanwhile, the CNTs with a laminated structure transfer and share the load. This multiply hybrid reinforcement structure of dispersed TiB2 and TiC particles along with CNTs lamination improves the mechanical properties of the resulting CNTs-TiB2-TiC/Cu laminated composites.

Effects of adding Si3N4 whiskers to ZrB2–SiC ceramics on microstructure, mechanical properties and oxidation resistance

ZrB2–SiC–Si3N4w ceramics (ZSNw) were prepared via the hot-pressing sintering method. The bending strength and fracture toughness of ZSNw at room temperature reached to 520 ± 24 MPa and 5.2 ± 0.16 MPa m1/2, respectively. The enhancement in mechanical properties is attributed to the grain refinement and attenuation of grain boundary induced by the homogeneous distribution of Si3N4 whiskers. The oxidation resistance of ZSNw were conducted at 1500 °C in an air atmosphere. Remarkably, after 10 h of oxidation, ZSNw remained excellent strength and toughness reaching at 589 ± 26 MPa and 4.8 ± 0.12 MPa m1/2, respectively. This oxidation resistance of ZSNw was mainly attributed to the gain refinement induced by Si3N4 whiskers, which effectively reduced the voids within the ceramic matrix. Therefore, this process promoted the densification and homogenization of the SiO2 protective barriers, accompanied with hindering the inward permeation of oxygen and the outward release of oxides.

Arc erosion behavior of Ag-8 wt.%ZrO2 contact materials with CuO additions

To clarify the effect of CuO on the arc erosion behavior of AgZrO2 contact materials, the Ag-8 wt.%ZrO2 contact materials without and with CuO addition were prepared by the combination of three-dimensional vibrating mixing and hot-pressing sintering, and the electrical contact tests were performed 5000 times on a JF04D electrical contact testing system. The effect of CuO additive on the arc erosion behavior of Ag-8 wt.%ZrO2 contact material was studied, and the arc erosion mechanism was discussed as well. The results show that an appropriate CuO addition can significantly improve the hardness, electrical conductivity and arc erosion resistance of Ag-8 wt.%ZrO2 contact material. At 0.5 wt%CuO, the optimal combination of relative density, hardness and electrical conductivity can be achieved, which are 99.48 %, 79.0 HV and 79.3 %IACS, respectively. Furthermore, the Ag-8 wt.%ZrO2 contact material with 0.5 wt%CuO addition exhibits the lowest arc energy and shortest arc duration, least mass loss, and silver splashing as well as the formation of pores are also significantly inhibited, displaying excellent arc erosion resistance. This can be ascribed to the improved electrical conductivity and enhanced interface bonding together with CuO decomposition under high temperature arc.

Cr-Diamond/Cu Composites with High Thermal Conductivity Fabricated by Vacuum Hot Pressing.

Chromium-plated diamond/copper composite materials, with Cr layer thicknesses of 150 nm and 200 nm, were synthesized using a vacuum hot-press sintering process. Comparative analysis revealed that the thermal conductivity of the composite material with a Cr layer thickness of 150 nm increased by 266%, while that with a Cr layer thickness of 200 nm increased by 242%, relative to the diamond/copper composite materials without Cr plating. This indicates that the introduction of the Cr layer significantly enhanced the thermal conductivity of the composite material. The thermal properties of the composite material initially increased and subsequently decreased with rising sintering temperature. At a sintering temperature of 1050 °C and a diamond particle size of 210 μm, the thermal conductivity of the chromium-plated diamond/copper composite material reached a maximum value of 593.67 W∙m-1∙K-1. This high thermal conductivity is attributed to the formation of chromium carbide at the interface. Additionally, the surface of the diamond particles in contact with the carbide layer exhibited a continuous serrated morphology due to the interface reaction. This "pinning effect" at the interface strengthened the bonding between the diamond particles and the copper matrix, thereby enhancing the overall thermal conductivity of the composite material.

Interfacial behavior and damage mechanism of Al-B4C/Al laminated composites under ballistic impact

The present study involved the fabrication of Al-B4C/Al laminated composites with a strong bonding interface using an integrated (or one-step) hot-pressed sintering method followed by hot rolling. A comprehensive analysis of the mechanical properties and interface behavior of Al-B4C/Al laminated composites under various loading conditions, particularly focusing on ballistic impact. Findings indicate that the laminated composite exhibits a high-strength interface bonding (greater than 318 MPa) facilitated by the continuous Al matrix, with no interlayer delamination occurring even after Charpy impact failure and ballistic penetration. The integrated interface promotes coordinate deformation between different component layers, enhancing the comprehensive mechanical performance of the Al-B4C/Al laminated composites. Moreover, the integrate interface of the Al-B4C/Al laminated plate enables a higher absorption of impact energy from projectiles, increasing by 10% and 70% compared to the monolithic and unbonded stacked plates, respectively.

Ultrahigh energy storage performance in BNT-based binary ceramic via relaxor design and grain engineering

Dielectric capacitors attract much attention for advanced electronic systems owing to their ultra-fast discharge rate and high power density. However, the low energy storage density (Wrec) and efficiency (η) severely limit their applications. Herein, Bi0.5Na0.5TiO3-K0.5Na0.5NbO3 binary ceramic is developed to obtain excellent energy storage performance with strong relaxor behavior, together with large polarization and distorted lattice calculated by first-principles calculations. The atomic-scale local structure analysis of 0.75Bi0.5Na0.5TiO3–0.25K0.5Na0.5NbO3 ceramic reveals distorted polarization distribution and small polar nanoregion related with the enhanced relaxation and low hysteresis. Finite element analysis demonstrates ultrafine grain and increased grain boundary density following hot-pressing sintering are crucial factors in significantly enhancing the breakdown strength (Eb). As a result, ultrahigh Wrec of 12.39 J/cm3 and η of 87.1 % are achieved at a superhigh Eb of 713 kV/cm. Encouragingly, excellent performance of temperature, frequency and fatigue stability at 400 kV/cm are obtained, and high power density of ∼ 306 MW/cm3 as well as fast discharge speed of ∼ 23.3 ns are also realized. This work proposes a simple binary design with strong relaxor behavior, and highlights the potential of grain engineering to achieve outstanding energy storage performance with great stability and excellent charge-discharge property for pulse power devices.

Ultrafine-grained refractory high-entropy alloy with oxygen control and high mechanical performance

Grain boundary engineering plays a significant role in the improvement of strength and plasticity of alloys. However, in refractory high-entropy alloys, the susceptibility of grain boundaries to oxygen presents a bottleneck in achieving high mechanical performance. Creating a large number of clean grain boundaries in refractory high-entropy alloys is a challenge. In this study, an ultrafine-grained (UFG) NbMoTaW alloy with high grain-boundary cohesion was prepared by powder metallurgy, taking advantages of rapid hot-pressing sintering and full-process inert atmosphere protection from powder synthesis to sintering. By oxygen control and an increase in the proportion of grain boundaries, the segregation of oxygen and formation of oxides at grain boundaries were strongly mitigated, thus the intrinsic high cohesion of the interfaces was preserved. Compared to the coarse-grained alloys prepared by arc-melting and those sintered by traditional powder metallurgy methods, the UFG NbMoTaW alloy demonstrated simultaneously increased strength and plasticity at ambient temperature. The highly cohesive grain boundaries not only reduce brittle fractures effectively but also promote intragranular deformation. Consequently, the UFG NbMoTaW alloy achieved a high yield strength even at elevated temperatures, with a remarkable performance of 1117 MPa at 1200 °C. This work provides a feasible solution for producing refractory high-entropy alloys with low impurity content, refined microstructure, and excellent mechanical performance.

Thermal Conductivity of AlSi12/Al2O3-Graded Composites Consolidated by Hot Pressing and Spark Plasma Sintering: Experimental Evaluation and Numerical Modeling

Functionally graded metal matrix composites have attracted the attention of various industries as materials with tailorable properties due to spatially varying composition of constituents. This research work was inspired by an application, such as automotive brake disks, which requires advanced materials with improved wear resistance on the outer surface as combined with effective heat flux dissipation of the graded system. To this end, graded AlSi12/Al2O3 composites (FGMs) with a stepwise gradient in the volume fraction of alumina reinforcement were produced by hot pressing and spark plasma sintering techniques. The thermal conductivities of the individual composite layers and the FGMs were evaluated experimentally and simulated numerically using 3D finite element (FE) models based on micro-computed X-ray tomography (micro-XCT) images of actual AlSi12/Al2O3 microstructures. The numerical models incorporated the effects of porosity of the fabricated AlSi12/Al2O3 composites, thermal resistance, and imperfect interfaces between the AlSi12 matrix and the alumina particles. The obtained experimental data and the results of the numerical models are in good agreement, the relative error being in the range of 4 to 6 pct for different compositions and FGM structure. The predictive capability of the proposed micro-XCT-based FE model suggests that this model can be applied to similar types of composites and different composition gradients.

Rapid preparation of Si3N4 ceramics with high thermal conductivity and low dielectric loss by fast hot-pressing (FHP) sintering

A series of Si3N4 ceramics with MgO and Y2O3 as sintering additives were successfully prepared by fast hot-pressing (FHP) sintering at the sintering temperature of 1700 °C, with the hold time of only 10 min and the whole sintering process of 36 min. The sintering behavior, densification process, microstructure, crystalline phase composition, bond composition, thermal conductivity and dielectric properties were systematically investigated. FHP reduces the sintering temperature and sintering time of Si3N4 ceramic compared to traditional solid-state method. The results of a series of tests have shown that the densification of Si3N4 ceramics and the phase transition from α-Si3N4 to β-Si3N4 can be facilitated by appropriate levels of additives, resulting in a dense, homogeneous and non-porous microstructure. Additionally, based on test results in this work, Si3N4 -4 wt.% Y2O3 -2 wt.% MgO exhibit the highest thermal conductivity of 78.16 W/mK, the dielectric constant of 8.50 and the dielectric loss of 5.52 × 10−4. The Si3N4 ceramics investigated in this work exhibit excellent properties for use of power semiconductor device packages, microwave devices, and power electronics. And also demonstrate the potential of FHP in laying the foundation for the further preparation of higher performance Si3N4 ceramics.

Investigation of mechanical characteristics of hot-pressed sintered tungsten based advanced shielding materials

This research aims to investigate the application of the hot pressing (HP) sintering process in the fabrication of W-B-Fe-Cr-C advanced shielding materials and analyze the relationship between their microstructure and mechanical properties. The findings reveal that the HP sintering process can effectively produce reactive sintered boride (RSB) materials with high density and engineering application size. The results indicate that the residual stress in RSB-HP improves its bending strength to some extent. Residual stress and granular structure are both related to phase aggregation during sintering. Microstructural analysis has unveiled the granular organizational characteristics and the pathways of crack propagation within the RSB-HP. These discoveries hold significant importance for comprehending the potential of the HP sintering process in the context of nuclear fusion shielding material preparation and provide a scientific foundation for further optimizing the sintering process and performance of RSB materials.

Enhancing mechanical properties and density of WC-Co with pressureless sintering via shell structure binder jetting additive manufacturing

The binder jetting (BJT) additive manufacturing (AM) process is suitable for producing complex WC-Co cemented carbide parts. To achieve near-full-density in the final parts, the hot isostatic pressing (HIP) sintering process is typically employed to enhance densification. However, HIP sintering requires high equipment specifications and is relatively more costly compared to conventional pressureless sintering. To improve the density of WC-Co parts printed by BJT AM under the pressureless sintering environment, the shell structure printing method was used in this study. The shell structure printing only jets binder to the model's outer profile, creating a shell that encapsulates the central powder, mitigates binder pyrolysis and residual effects on particle densification, and enhances post-sintering density. In this work, the effect of shell thickness, binder type, and printing layer thickness on the density and mechanical properties of the WC-12Co parts under pressureless sintering conditions were investigated. The results show that the density and mechanical properties of the WC-12Co parts significantly improved with the decreasing shell thickness. Specifically, the WC-12Co printed using shell structure achieves a relative density of over 98% and a transverse rupture strength (TRS) of 1954 MPa after pressureless sintering, a result comparable to BJT printed samples treated with HIP sintering. Moreover, the results indicate using a binder with lower residual carbon content and smaller printing layer thickness has a more positive effect on improving density and mechanical strength when employing the shell structure printing method. Microstructure morphology and phase analysis results indicate that the shell structure printing method does not affect the growth of WC grains in the shell and center regions, nor does it influence its phase composition. The shell structure printing method offers a new approach to the manufacturing of near-full-dense WC-Co materials using the BJT process.

Immobilization of 137Cs in NaY type zeolite matrices using various heat treatment methods

The accumulation of liquid radioactive waste presents a significant global challenge, necessitating effective strategies for safe management. This study investigates the immobilization of 137Cs radionuclides, a prominent component of liquid radioactive waste, in ceramic matrices based on 137Cs-saturated NaY Faujasite zeolite. Various thermal methods were employed, including cold pressing and sintering, cold pressing and sintering with microwave assistance, hot pressing, and spark plasma sintering, to enhance immobilization capabilities. Zeolite powder was saturated with 137Cs radionuclides using an adsorption technique with low-activity model liquid radioactive waste. In-situ XRD and dilatometry methods were used to study the thermal behavior during NaY Faujasite annealing. The influence of calcination temperature on lattice parameters and crystallite size was assessed. Immobilization effectiveness was evaluated through relative density, Vickers microhardness, compressive strength, and metal ion leaching kinetics. Mechanistic evaluation was performed using XRD and SEM-EDX studies. Results showed that spark plasma sintering exhibited the highest efficiency for immobilizing 137Cs radionuclides in NaY Faujasite matrices. This research contributes to liquid radioactive waste management by providing insights into the thermal behavior and enhanced immobilization capabilities of ceramic matrices.

Unraveling Lattice-Distortion Hardening Mechanisms in High-Entropy Carbides.

Uncovering the hardening mechanisms is of great importance to accelerate the design of superhard high-entropy carbides (HECs). Herein, the hardening mechanisms of HECs by a combination of experiments and first-principles calculations are systematically explored. The equiatomic single-phase 4- to 8-cation HECs (4-8HECs) are successfully fabricated by the two-step approach involving ultrafast high-temperature synthesis and hot-press sintering techniques. The as-fabricated 4-8HEC samples possess fully dense microstructures (relative densities of up to ≈99%), similar grain sizes, clean grain boundaries, and uniform compositions. With the elimination of these morphological properties, the monotonic enhancement of Vickers hardness and nanohardness of the as-fabricated 4-8HEC samples is found to be driven by the aggravation of lattice distortion. Further studies show no evident association between the enhanced hardness of the as-fabricated 4-8HEC samples and other potential indicators, including bond strength, valence electron concentration, electronegativity mismatch, and metallic states. The work unveils the underlying hardening mechanisms of HECs and offers an effective strategy for designing superhard HECs.

Optimisation of the magnetic properties of soft-magnetic composites through an interfacial solid-phase reaction based on hot-pressing sintering and secondary-magnetic-phase addition

An effective method to improve the magnetic properties of soft-magnetic composites (SMCs) is insulation coating, which is achieved by inducing an interfacial solid-phase reaction via hot-pressing sintering. Herein, an interfacial solid-phase reaction was induced at the SMC interface through salt compound decomposition and the doping of carbonyl iron powder (CIP). Furthermore, FeSiAl-based SMCs with various CIP amounts were prepared. Results show that during hot-pressing sintering, calcium acetate coated on the FeSiAl matrix decomposes. Furthermore, the generated reactive oxygen species cause Si and Al migrations to the heterogeneous interface; in combination with the decomposition product CaO, these migrations result in the in situ formation of a CaSiO3·SiO2·Al2O3 composite insulation layer on the matrix surface. CIP added to the hydrothermal insulation coating exhibits good plasticity, and its combination with the coating layer improves the compressibility of composite powders and eliminates pores within SMCs. In hot-pressing sintering, CIP addition hinders the conversion of Si to SiO2, resulting in excess reactive oxygen species that react with Al in the FeSiAl matrix to yield a higher Al2O3 content. With an increase in the CIP amount, more Si diffuses into CIP such that the magnetic phase inside FeSiAl-based SMCs changes from a single Al0.3Fe3Si0.7 phase to a mixed phase comprising an Al0.3−xFe3Si0.7−y phase, CIP and CIP–Si. However, excessive CIP addition can cause the re-formation of pores inside SMCs and deterioration of magnetic properties. By changing CIP addition amounts, the magnetic properties of SMCs are precisely regulated. When the CIP addition amount is 9 wt%, the prepared SMCs exhibit optimal magnetic properties, with the highest saturation magnetisation of 134.5 emu/g and permeability of 44.1 at 10 mT and 500 kHz, along with a core loss as low as 198.8 kW/m3 at 20 mT and 100 kHz.

Hot-pressing-oriented graphene in Si3N4 composites for enhanced electromagnetic wave absorption in X and Ku bands

In this study, the oriented graphene within graphene/Si3N4 composites was successfully achieved by two-step hot-press sintering. Microstructure analysis revealed that the graphene sheets were well dispersed in the Si3N4 matrix and oriented perpendicular to the applied stress. The composites exhibited effective electromagnetic wave (EMW) absorption capabilities and good mechanical properties. The effective absorption bandwidth (EAB) was 9.63 GHz, nearly covering the entire X and Ku bands (8.2–18 GHz), and the minimum reflect loss (RL) was −24.23 dB when the graphene content reached 7 wt% at a thickness of 2.02 mm. Meanwhile, the oriented graphene/Si3N4 composites demonstrated a bending strength of 576.66 MPa and a fracture toughness of 8.40 MPa·m1/2. The EMW absorption in these composites should be primarily due to polarization relaxation loss and conductivity loss, and the toughening mechanism should involve the graphene pull-out, crack bridging, and crack deflection. The graphene/Si3N4 composites have a promising application in structurally integrated functional materials.

Effect of the TiB2 content on the mechanical and tribological properties of TiB2/AZ91 composites fabricated by vacuum hot-press sintering process incorporating vacuum ball milling

Magnesium alloys have poor strength and wear resistance, restricting their application greatly, while Mg matrix composites can improve these deficiencies. TiB2/AZ91 composites with high TiB2 content were prepared by vacuum hot-press sintering process incorporating vacuum ball milling. The effects of TiB2 content on the microstructure, mechanical properties and tribological properties of the composites were investigated in detail. The results suggested that the TiB2 particle exhibited good bonding with the Mg matrix. With the increasing TiB2 content, the ultimate tensile strength, yield strength and elongation of TiB2/AZ91 composites firstly increased and then decreased, while the wear rate and wear surface roughness presented an opposite trend, and the hardness and coefficient of friction gradually increased. The composites with 5 wt% TiB2 obtained the maximum tensile properties (UTS: 234 MPa YS: 91 MPa EL: 7.3 %). This improvement in mechanical properties was attributed to the uniform distribution of TiB2 particles and the well bonding at the interface. The strengthening mechanisms were found to be the load transfer strengthening and the thermal mismatch strengthening. Furthermore, the composites with 15 wt% TiB2 demonstrated the lowest wear rate of 1.06×10−6 mm3/Nm and lowest wear surface roughness of 2.971 μm. This wear resistance was enhanced because of the significant increasing in hardness. The dominant wear mechanisms observed in TiB2/AZ91 composites were abrasive wear and oxidation wear.

Enhanced mechanical/electrical properties of in situ synthesized SiC-TiB2 ceramic composites by reactive hot-pressing sintering

In this work, in situ formed TiB2-reinforced SiC ceramic composites were prepared by reactive hot pressing using SiC, TiC, B4C, and Si as raw materials. Phase composition, microstructure, and mechanical as well as electrical properties were investigated. The formation of the TiB2 phase could be realized from the reaction among TiC, B4C, and Si. In the sintered SiC–TiB2 ceramic composites, the content of α-SiC decreased while that of the in situ formed TiB2 increased. In addition, residual Si only existed in the SiC–TiB2 ceramic composites with in situ TiB2 below 20 mol%. Notably, the comprehensive performance of the SiC–TiB2 ceramic composites was enhanced with the increase of TiB2 content due to the reduction of pores and residual Si. Finally, nearly fully dense SiC–TiB2 ceramic composites were obtained when in situ formed TiB2 was above 20 mol%. The SiC–TiB2 ceramic composites, with in situ TiB2 of 30 mol%, exhibited hardness of 26.9 ± 2.3 GPa, fracture toughness of 6.83 ± 0.6 MPa m1/2, and electrical resistivity of 0.3 mΩ cm, respectively.

Comparative study on microstructure evolution, mechanical properties, and wear behavior of TiC and B4C single-reinforced and hybrid-reinforced Al–Mg–Si alloys by vacuum hot-press sintering

To explore the variances between single-reinforced and hybrid-reinforced Al–Mg–Si alloys with TiC and B4C, 10 wt.%-(TiC + B4C)/6061Al, 10 wt.%-B4C/6061Al, 10 wt.%-TiC/6061Al and 6061Al were prepared via wet mixing for 8 h followed by vacuum hot-press sintering at 580 °C and 30 MPa for 2 h. Microstructure evolution, mechanical properties, and wear behavior were investigated in this study. The results show that unlike single reinforcement of TiC, single reinforcement of B4C and hybrid reinforcement of TiC and B4C altered the distribution of Si and facilitated the in-situ formation of SiC. Both single reinforcement and hybrid reinforcement resulted in mixed fracture characteristics of ductile fracture and cleavage fracture, while hybrid reinforcement of TiC and B4C demonstrated superior strength and plasticity matching. At equivalent particle mass fractions, single reinforcement of TiC was more conducive to inducing recrystallization during sintering, followed by single reinforcement of B4C, and hybrid reinforcement of TiC and B4C had the least effect. At equivalent particle mass fractions, single reinforcement of B4C had the most significant effect on improving the wear resistance, followed by hybrid reinforcement of TiC and B4C, and single reinforcement of TiC had the least effect. All particle addition methods demonstrated a mixed wear mechanism involving abrasive wear, adhesive wear, and spalling wear. This study provides valuable insights into the development of aluminum matrix composites.

Effects of different binder systems on the characteristics of metal-based diamond composites fabricated via fused deposition modeling and sintering technology

In material extrusion of metal-based composites, binder system plays a vital role and its performance directly influences the quality of the final product and process efficiency. Despite different binder systems have been produced, most studies only concentrated on single binder system without comparison between different binder systems. In this work, two different binder systems were used to fabricate metal-based diamond composites by fused deposition modeling and sintering technology. Morphology of printed metal-based composites samples were compared. Thermal properties of composites samples with different binder systems were analyzed via TG-DSC test, and debinding was carried out at heating rate of 5 °C/min and 2 °C/min, respectively. Then the brown samples were densified via hot-pressing sintering, and the sintered samples were evaluated by scanning electron microscopy, hardness tester and universal testing machine. During the printing process, the feedstock using TP-based binder system exhibited better printing performance compared with that using the PW-based binder system. The results also revealed that appropriate nozzle temperature should be determined according to the thermal properties of the feedstocks so as to minimize printing defects. The debinded samples with different binder systems can retain structural integrity when the heating rate controlled properly. As for the samples after sintering, it has to be highlighted that the hardness on the top surface of the sintered sample was higher than the hardness on the side because of different deposition characteristics. In addition, the samples using TP-based binder presented a more uniform microstructure and thus obtained better flexural strength and relative density. It can be concluded that the TP-based binder is preferable as it contributes to better performance of the metal-based diamond composites compared with the PW-based binder.

Preparation of high-density and excellent bending strength pure tungsten target by hot oscillatory pressing sintering and its magnetron sputtering coating

The high-strength, high-density pure tungsten (W) targets were fabricated using hot oscillatory pressing (HOP) sintering. This study examined the influence of sintering temperature, oscillation frequency, amplitude, and median pressure on the relative density, grain size, and bending strength of the tungsten targets. A tungsten target exhibiting a relative density of 99.51%, a grain size of 2.95 μm, a bending strength of 1200.1 MPa, and a purity of 99.95% was synthesized at a sintering temperature of 1600 °C, an oscillation pressure of 60 ± 15 MPa, and a frequency of 1 Hz. Grain rearrangement and plastic deformation (dislocation movement and grain boundary slip) were identified as the primary mechanisms for grain refinement and densification, respectively. The key strengthening mechanism was sub-grain boundary strengthening. The optimal tungsten target was utilized for magnetron sputtering on a reduced activation ferritic/martensitic (RAFM) steel substrate. The effects of sputtering time, power, deposition pressure, and substrate temperature on the crystallinity, roughness, thickness, and bonding force of the tungsten films were investigated. The optimal magnetron sputtering process was achieved by sputtering for 45 min at a power of 60 W, a deposition pressure of 15 Pa, and a substrate temperature of 100 °C. This resulted in dense W films with excellent comprehensive properties, including a roughness of Ra = 8.73 nm, Rq = 3.34 nm, a thickness of 999.05 nm, and a bonding force of 2.57 N.