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HEAVY ALLOYS
ALLOYS
Kennametal Densalloy
ENGINEERING GUIDE
TUNGSTEN
HEAVY ALLOYS
Kennametal Densalloy
Celebrating more than 75 years as an industrial technology leader,
Kennametal Inc. delivers productivity to customers seeking peak
performance in demanding environments. The company provides
innovative wear-resistant products, application engineering and
services backed by advanced material science, serving customers
in 60 countries across diverse sectors of aerospace, earthworks,
energy, industrial production, transportation and infrastructure.
Kennametals broad and innovative custom solutions are derived
from advanced materials sciences, application knowledge,
design expertise, customer support, and commitment to a
sustainable environment.
These solutions are all developed to customer requirements:
Fabricated and assembled engineered components for
wear applications, balance weights, vibration damping,
and radiation shielding.
Earth cutting technologies for underground and surface
mining and construction products.
Surface technologies such as wear- and corrosion-resistant
coatings, claddings, and plates for challenging applications.
Contents
SECTION 1
SECTION 8
Radiation Attenuation
28
SECTION 2
SECTION 9
32
P/M implications
Designing for maximum mechanical integrity
Minimizing WHA part cost via design
SECTION 3
WHA Compositions
SECTION 10
34
SECTION 4
WHA Production
11
SECTION 11
38
SECTION 5
Post-Sinter Processing
15
Enhanced ductility/toughness
Enhanced strength/hardness
SECTION 6
Sintered Microstructure
18
SECTION 12
42
SECTION 7
WHA Properties
22
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SECTION 1
shielding, and tools for metal forming and cutting that are
temperatures required.
(0.70 lbs/in3).
FIGURE 1
He
Li
Be
Ne
Na
Mg
Al
Si
Se
Cl
Ar
Ca
Sc
Ti
Cr
Mn
Fe
Co
Ni
Cu
Zn
Ga
Ge
As
Se
Br
Kr
Rb
Sr
Zr
Nb
Mo
Tc
Ru
Rh
Pd
Ag
Cd
In
Sn
Sb
Te
Xe
Cs
Ba
La
Hf
Ta
Re
Os
Ir
Pt
Au
Hg
Tl
Pb
Bi
Po
At
Rn
Fr
Ra
Ac
Ce
Pr
Nd
Pm
Sm
Eu
Gd
Tb
Dy
Ho
Er
Tm
Yb
Lu
Th
Pa
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Counter Weights
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SECTION 2
techniques
High
elastic stiffness
Low
Lower
A
Preservation
conductivity
Low
Ability
friendliness
These characteristics position WHA as an ideal material for
of Pb or U in existing applications.
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Inertial
helicopter rotors.
Center
security applications.
Pb-free
energy storage.
High
Weight
mechanical response.
Low
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TABLE 1
Material
Density (g/cc),
[lb/in3]
Solidus or
MP (C)
Modulus
(GPa)
CTE
(ppm/C)
Therm. Cond.
( W/m-K )
Mg
1.7 [0.06]
629
44
26
159
Al
2.7 [0.10]
660
69
24
210
Ti
4.5 [0.16]
1670
116
17
Fe
7.9 [0.28]
1536
207
12
76
Pb
11.4 [0.41]
328
14
29
33
Ta
16.6 [0.60]
2996
186
54
WHAs (typ.)
17.1 18.6
[0.62 0.67 ]
1450
310 380
~5
~80
19.1 [0.69]
1132
160
19
27
19.3 [0.70]
3420
410
163
Au
19.3 [0.70]
1064
80
14
301
Pt
21.4 [0.77 ]
1769
171
69
Ir
22.5 [0.81]
2443
524
147
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SECTION 3
WHA Compositions
WHAs typically consist of 90 98 wt.% W in combination with some mix of
Ni, Fe, Cu, Co, and/or Mo making possible densities approaching 19 g/cc.
TABLE 2
Nom. W (wt.%)
90
16.85 17.25
92.5
17.15 17.85
95
17.75 18.35
97
18.25 18.85
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Densalloy Grade
SD170
17.15
Dens21
17.19
SD175
17.65
Dens23
17.70
SD180
18.16
Dens25
18.20
SD185
18.60
Further, with the exception of AMS 7725E, material certification is based on the testing of coupons not actual
parts. These general specifications allow a rather wide
range of property variation that may not be sufficient for
all WHA applications. In such cases, end users having
need for more precise knowledge of the density, tensile,
and other properties of full size parts should consider an
application specific destructive testing plan in addition
to these industry standard material specifications when
purchasing WHA for such uses. Supplemental material
specification becomes essential when WHA is purchased
in mechanically processed forms or when special postsinter heat treatments have been applied. In contrast to
typical commercial practice, military material specifications
for WHA typically define a specific alloy, post-sinter processing, and a testing plan.
TABLE 3
Ternary
Quaternary
System
Advantages
Disadvantages
W-Ni-Cu
W-Ni-Fe
W-Ni-Co
W-Ni-Fe-Co
W-Ni-Fe-Mo
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TABLE 4
1.5 to 2
Used in many older alloy formulations. Sintering is more sluggish due to lower W solubility in the
molten binder during LPS. These alloys offer equivalent mechanical properties in the as-sintered
state as higher %Ni alloys but slightly lower post-sinter processed properties than the latter.
Preferred composition range of commercial W-Ni-Fe alloys, offering best overall properties in
the as-sintered and vacuum annealed states and freedom from intermetallics over a wide range
of cooling rates.
6 to 7
Increased %Ni causes substantial drop in magnetic permeability of the binder, achieving a R
as low as 1.01. This alloying option provides a useful alternative to W-Ni-Cu in applications
where a non-magnetic alloy is required. Slow cooling rates from sintering should be avoided.
Very high Ni/Fe ratio WHAs require resolutionization/quench for control of the Ni4 W intermetallic.
While not commercialized, such WHAs are capable of providing mechanical properties exceeding
that of lower Ni/Fe ratio alloys.
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Metastable W retained in matrix solid solution from sintering and resultant properties.
Charpy
(ft lbs)*
Alloy
Sintering
W (wt.%)
UTS (ksi)
EL (%)
HRC
solid state
~18
too brittle
liquid phase**
~23
135
35
28
220
liquid phase**
~40
140
40
31
300+
10
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SECTION 4
WHA Production
Although a variety of possible fabrication technologies exist and may be utilized
for very specific applications, virtually all WHA manufacture worldwide utilizes
the conventional powder metallurgy (P/M) approach of press and sinter.
materials selection
Powder
homogeneous blend.
Pressing
shaped tooling.
Sintering
Optional
specific properties.
Machining
Application
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or other.
11
of recovery.
Starting Powders
The W metal powder (and additionally any Mo) used in
WHA is produced by H2 reduction of an oxide of the parent
metal. Transition metal powders used are typically of
carbonyl origin. All powders are very fine typically in
the 1.5-8 m FSSS size range. The use of very pure powders
is critical for attaining high mechanical properties in the
sintered state.
For more precise shaped pressings, conventional punchand-die hard tooling is necessary. In many cases, depending
on part geometry and pressing technique to be used,
additives are introduced into the blend for enhancement
of specific characteristics:
Increase
Blending
Introduction
Pressing/Green Shaping
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Given the density (up to ~11 g/cc [or ~0.38 lb/in3]) yet
will have achieved near full density while still in the solid state.
Sintering
FIGURE 1
Pressed WHA shapes are positioned on ceramic slabs prior to insertion into
a pusher type furnace for LPS in a flowing ambient pressure H2 atmosphere.
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13
Sintered Quality
mechanical properties.
developed subscale.
14
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SECTION 5
Post-Sinter Processing
For the majority of commercial mass property end uses of WHA,
as-sintered properties as addressed by specifications such as
AMS-T-21014 and ASTM B777 are sufficient.
Aileron Weight
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15
but very common for military uses such as long rod kinetic
Post-Sinter Deformation
for Enhanced Strength
Deformation processing of WHA is performed either to:
(1) efficiently manufacture a specific shape or (2) to increase
the strength and hardness of the alloy. (The former will be
addressed later under Forming, as this section deals only
with the latter.) For the goal of alloy strengthening by strain
hardening, deformation operations are typically performed
at room temperature or only slightly above the DBTT.
16
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FIGURE 2
91W-Ni-Co
1600
UTS (MPa)
1500
1400
SWAGED
+ AGED
91W-Ni-Fe
1300
SWAGED
1200
SWAGED
+ AGED
1100
1000
800 |
0
UNWORKED
SWAGED
900
|
5
|
10
|
15
|
20
|
25
|
30
UNWORKED
|
35
|
40
ELONGATION (%)
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17
SECTION 6
Sintered Microstructure
With the exception of some specialty ordnance alloys, all commercial WHAs
are two phase metal/metal matrix composites in which the W phase is almost
always present in a spheroidized form for maximum part ductility/durability.
in Figure 3.
FIGURE 3
Matrix Phase
Enables LPS
Contains W in metastable solid
solution
18
100 m
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FIGURE 4
100 m
100 m
Solid State
Sintered
Condition
Fully Liquid
Phase Sintered
Full
Sintered Density
Full
Poor
Durability/Machinability
Good
<1
~12
~1
~25
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19
The
tensile properties.
Large
property information for parts must develop a supplemental quality plan that specifies where destructive
test samples are to be excised.
As part geometry affects the rate of heat up in sintering,
the testing of smaller but equivalent thickness coupons
may not provide results representative of actual parts.
20
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FIGURE 5
FIGURE 6
100 m
100 m
FIGURE 7
FIGURE 8
20 m
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20 m
21
SECTION 7
WHA Properties
Tensile Properties
content;
metallurgical
binder
phase composition.
FIGURE 9
40
VA
VA+Q
35
EL (%)
30
FIGURE 9B
25
300
20
350
15
1000
200
ENERGY (J)
10
950
900
UTS (MPa)
850
150
100
800
50
750
|
0
|
2
|
4
|
6
|
8
|
10
Ni/Fe RATIO
22
|
12
|
14
|
16
| 700
18
0 |
0
|
2
|
4
|
6
|
8
|
10
|
12
|
14
|
16
|
18
Ni/Fe RATIO
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Elastic Modulus
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23
Impact Properties
Hardness
Magnetic Properties
WHA industry standards use a relative magnetic permeability
(R) value of 1.05 as the threshold of magnetic character
magnetic to imply attraction by a magnet (capture of
flux lines) rather than the WHA itself exhibiting substantial
magnetization. For simplicity, magnetic permeability of WHA
is typically measured using a Severn Gauge as described
in ASTM A342. W-Ni-Fe alloys with Ni/Fe<6 exhibit a weak
ferromagnetic response. As can be seen in Table 6, alloys
with Ni/Fe=7 exhibit only very feeble ferromagnetism
comparable to that of some austenitic stainless steels
and easily satisfying the requirement for nonmagnetic
classification. Even the highest permeability WHA is far less
magnetic than common steels. For the very few applications
that require true paramagnetic character, W-Ni-Cu alloys
must be chosen. Any significant amount of Fe contaminant in
W-Ni-Cu will slightly compromise their paramagnetic behavior.
24
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Thermal Properties
TABLE 6
AMS-T-21014
Class
Permeability
( R )
Mumetal (ref.)
na
20000
na
>1000
5.0 5.5
~1.01
90W-Ni-Cu
1.00
4.5 5.0
~1.01
4.0 4.5
~1.01
1.6 2.0
Pure W
na
1.00
WHA Composition
Acoustic Properties
FIGURE 10
140
UTS, 0.2%OYS (KSI), EL X10 (%)
120
100
80
60
40
20
0 |
-100
|
0
|
100
|
200
|
300
|
400
|
500
|
600
|
700
|
800
|
900
EL
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YS
UTS
25
very low at 4.2 ppm/C (for 20 200C), the CTE for common
Wing Weights
26
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Corrosion Behavior
FIGURE 11
20 m
can be applied.
27
SECTION 8
Radiation Attenuation
The shielding of penetrating radiation is one of the principal
Offers
Possesses
High
Minimum
reactions
Low
Available
60
for attenuation of beta radiation, and its use for such is in fact
28
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TABLE 7
Density
(g/cc)
304 SS (Fe-19Cr-9Ni)
0.428
mixed
8.0
1400
Cu
0.471
29
8.96
Pb
0.667
82
WHA (W-Ni-Fe)
0.953 1.04
W
U
CTE
(ppm/K )
UTS
(MPa)
16
17
515
1083
390
17
<365
11.35
328
33
29
~21
mixed
17.1 18.5
~1450
~70 100
~5.8 4.8
870
1.076
74
19.3
3420
160
4.2
980
1.217
92
19.1
1132
27
19
400
ln (0.1) = -0.953 x
x = 2.42 cm
T = exp -( x)
-1
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29
TABLE 8
SD170
SD175
SD180
SD185
Dens21
Dens23
Dens25
W ref.
Pb ref.
U ref.
0.12
.053
.051
.048
.046
.053
.050
.048
.043
.058
.028
0.14 99mTc
.078
.074
.071
.068
.079
.074
.071
.064
.085
.040
0.20
.186
.178
.169
.163
.186
.178
.169
.153
.204
.094
0.36 131I
.619
.591
.566
.549
.618
.589
.565
.519
.722
.340
0.47 192Ir
.933
.893
.863
.838
.933
.893
.861
.795
1.14
.509
0.51 from +
1.05
1.01
.960
.933
1.04
.993
.960
.890
1.30
.637
0.66 137Cs
1.41
1.36
1.31
1.28
1.40
1.35
1.31
1.22
1.83
1.54
1.00
2.10
1.99
1.92
1.88
2.04
1.98
1.92
1.80
2.86
1.54
1.25 60Co
2.42
2.35
2.28
2.22
2.41
2.34
2.28
2.14
3.46
1.91
2.22 H(n,)
3.13
3.05
2.95
2.88
3.12
3.04
2.95
2.78
4.54
2.58
6.00
3.27
3.16
3.05
2.96
3.27
3.15
3.05
2.84
4.63
2.66
10.0
2.93
2.82
2.72
2.64
2.92
2.82
2.71
2.52
4.09
2.34
20.0
2.39
2.28
2.20
2.14
2.38
2.28
2.20
2.02
3.27
1.88
The above values are estimates calculated using the NIST XCOM routine and do not include any buildup factor.
Actual required thickness should be empirically verified before final shielding design and/or use.
steps) for nesting. The steps serve both for mechanical align-
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FIGURE 12
Source
Radiation Leakage
POOR
GOOD
BETTER
TABLE 9
Element
760
18
Ni
4.5
Fe
2.6
Al
0.23
Pb
0.172
for use in a primary neutron shield due to its weight and cost,
WHA may still play an important secondary shielding role in
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31
SECTION 9
Locate
Protect
FIGURE 13
The ability to fabricate large panels of WHA is limited by the P/M process.
Approaching such needs in a modular fashion often make large components possible with minimal changes
to functionality or support structures.
ORIGINAL REQUIREMENT
32
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Design
Minimize
net shape. For this majority case, near net shape blanks
Make
removal operations.
Ensure
33
SECTION 10
Milling
Sectioning
Turning
Sharp insert edges are vital for minimizing cutting force. Initial
jet, and laser cutting should never be used with WHAs. Such
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TABLE 10
Carbide
Grade
Rake
Clearance
Edge
Condition
Tooth Load
(in)
Depth of Cut
(in)
Speed
(sfpm)
Roughing
K10
-7 0
honed
0.005 0.015
0.030 0.125
200 400
Finishing
K10
0 +7
0 -11
sharp
0.003 0.010
0.005 0.030
300 500
TABLE 11
Carbide
Grade
Rake
Clearance
Edge
Condition
Feed Rate
(in/rev)
Depth of Cut
(in)
Speed
(sfpm)
Roughing
K10
-7 0
honed
0.005 0.020
0.030 0.125
200 350
Finishing
K10
0 +7
0 -11
sharp
0.005 0.010
0.005 0.015
250 400
Grinding
Tapping
for WHA due to the high resultant torque on the tap shank
should be used.
Drilling
work contact area include the use of larger pilot hole sizes,
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35
Forming
Joining
low speed and with generous tool radii. Slight heating of the
Rudder Weight
36
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Brazing
FIGURE 14
the W phase and the binder, WHAs are not readily weldable
as microcracking and selective binder element volatilization
can occur in the vicinity of a weld. When a thermal joining
technique is required, brazing provides a means of joining
WHA to itself or other metals. Brazing is best performed in
a hydrogen atmosphere furnace to protect the WHA parts
from oxidation and also permit fluxless joining. Compatible
filler metals include pure Cu, monel 400, and standard
AWS defined Ag-Cu brazing alloys such as BAg-13a. Filler
alloys containing S, P, Zn, Cd, or Al should be avoided due
to possible interfacial embrittlement. Brazing temperature
constraints and the end application generally determine
optimum filler metal choice. As with any brazing operation,
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37
SECTION 11
There
conductivity.
are considered.
There
permeability.
Attainable
TABLE 12
onset of fracture.
Magnetic
+7%
+1.5 g/cc
typ. -75%
the 93% W content for WHA as the optimum for long rod
38
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Aerospace Counterweight
WHA has been widely used for various aerospace
Radioisotope Transport/
Storage Container
TABLE 13
Density
(g/cc)
Tensile
Strength
Stiffness
Machinability
Toxicity
Radioactivity
Material Cost
Steel
~7.9
moderate
medium
excellent
high
none
low
Lead
~11.3
very low
very low
very low
high
none
low
WHA
17.0 18.5
moderate
high
excellent
low
none
moderate
DU
18.7 19.1
moderate
medium
special
high
present
moderate
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39
CT Scanner Collimator
the x-ray beam angle for each tomographic image slice. The
of 0.030 in thick. A ductile Class 1 WHA would provide maximum yield out of rolling thus enabling a lower part cost
than Cu sheet for 120 keV x-rays. Rolled WHA sheets are easily
velocity falloff during flight, fin stabilized long rods (L/D typically
TABLE 14
UTS (ksi)
EL (%)
Hardness (RC)
Charpy (J)*
As-sintered
125
15
28
Vacuum annealed
130
25
28
Quenched
135
32
29
200
Swaged 15%RA
160
16
39
150
Swaged 25%RA
175
14
40
95
200
44
60
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TABLE 15
Material
Modulus
(Mpsi)
Damping
Density
(g/cc)
4140 steel
30
low
7.9
Class 2 WHA
52
moderate
17.5
WC-10Co
90
low
14.5
High
Strength
Low
environment
Machinable
geometric detail
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41
SECTION 12
42
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Kennametal Inc.
1297 County Line Rd
Madison, AL 35756
Tel: +1 800 221 4273
Fax: +1 800 221 1895
Email: k-mdsn.inside-sales@kennametal.com
EUR O P E
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DISCLAIMER
Although considerable attention has been
devoted to providing accurate and useful
information, Kennametal is not responsible
for the accuracy or any outcome resulting
from the use of the information contained
in this document. It is the sole responsibility
of the purchaser to determine proper
material, condition, design, and safe use
of our products.
W O R LD HE AD QU ARTE RS
Kennametal Inc.
1600 Technology Way
Latrobe, PA 15650
USA
Tel: +1 800 446 7738
E-mail: ftmill.service@kennametal.com
EUR OPE AN HE AD QU ARTE R S
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