Microstructure And Property Tuning Of Cu-W Pseudo-Alloys And W Free Alternatives Consolidated By Electro-Sinter-Forging: Processing And Applications

Abstract

This work investigates the mechanical and electrical properties of copper–tungsten (Cu–W) pseudo-alloys and W-free alternatives consolidated through Electro-Sinter-Forging (ESF) for manufacture of electrode materials, notably for resistance welding and electro-discharge machining.ESF is an advanced Field Assisted Sintering Technique (FAST) combining pulsed high current and rapid uniaxial pressing to consolidate powders within milliseconds. The short thermal cycle enables full densification while limiting grain growth and long-range diffusion. Powder mixes prepared by attritor milling exhibit high material homogeneity and fine microstructures, preserved during the ESF cycle, enabling tailored hardness and electrical conductivity in the material. ESF-processed W75–Cu materials exhibit hardness from 250 to 350 HV, electrical conductivity from 18.5 to 24.5 MS|m, and tensile strength up to 500 MPa. The resulting properties meet the requirements specified in ISO 5182:2016, providing a cost-effective alternative to press-and-sinter or liquid-infiltrated Cu–W.In conclusion, developments leading to novel electro-sinter-forged tungsten-free Cu–Mo–TiN composites will be illustrated.