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Die-less manufacturing of tube by diffusion bonding of unit rods made of tungsten heavy alloy

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Abstract

A die-less method to manufacture tubes by diffusion bonding of rods made of tungsten heavy alloys was developed and characterized. Tungsten heavy alloys are pseudo-alloys of tungsten (W) with small amounts of lower-melting-point binder metals, typically Ni and Fe, and they are widely used in tubular shapes. Due to the excessively high consolidation temperature for W, the fabrication of components is normally done by sintering of powder compacts. During the sintering of W–Ni–Fe alloys, the partially melted Ni–Fe binder metal wets the tungsten powder particles and provides a soluble diffusion network for rapid sintering. However, as the binder metals partially liquefy, this process results in gravity-induced slumping, leading to distortion near the bottom section of the tubular part. This gravity-induced slumping creates significant difficulties during the production of tubular structures. A rod shape is the most stable shape to avoid slumping during sintering. Thus, a method to manufacture tubular tungsten heavy-alloy parts via joining of sintered rods by diffusion bonding was developed. Using an analytical model, the dimensions of the unit rods for fabrication of the target tube shape have been designed. An industry-applicable tube manufacturing process was well characterized, and the feasibility of the process was confirmed.

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Funding

This work was partially supported by a National Research Foundation of Korea (NRF) grant, funded by the Korean government (MSIP) (no. 2012R1A5A1048294).

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Authors and Affiliations

  1. R&D Center, Poongsan, 2606-10 Hokook-ro, Gyeongju, Gyeongsangbuk-do, Republic of Korea

    Zu Seong Park

  2. Department of Metallurgical and Materials Engineering, Colorado School of Mines, 1500 Illinois St., Golden, CO, 80401, USA

    Chester J. VanTyne

  3. Department of Aerospace Engineering, Pusan National University, 30 Jangjeon-dong, Geumjeong-gu, Busan, 46241, Republic of Korea

    Jeong Kim

  4. School of Mechanical Engineering, Pusan National University, 30 Jangjeon-dong, Geumjeong-gu, Busan, 46241, Republic of Korea

    Tae Woo Hwang, Yangjin Kim & Young Hoon Moon

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  1. Zu Seong Park
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Correspondence to Young Hoon Moon.

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Park, Z.S., VanTyne, C.J., Kim, J. et al. Die-less manufacturing of tube by diffusion bonding of unit rods made of tungsten heavy alloy. Int J Adv Manuf Technol 106, 1213–1221 (2020). https://doi.org/10.1007/s00170-019-04668-0

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