Synthesis of ultrafine/nanocrystalline W–(30–50)Cu composite powders and microstructure characteristics of the sintered alloys

Ultrafine/Nanocrystalline W–Cu composite powders with various copper contents (30, 40 and 50 wt.%) have been synthesized by sol-spray drying and a subsequent hydrogen reduction process. The powders were consolidated by direct sintering at temperatures between 1150 and 1260 °C for 90 min. The powder characteristics and sintering behavior, as well as thermal conductivity of the sintered alloys were investigated. The results show that the synthesized powders exist in ultrafine composite particles containing numerous nanosized particles, and the composition distributed very homogeneously. As the copper contents increase, the grain size of the powders decreases. The subsequent sintered parts show nearly full density with the relative density more than 99% at the temperature of 1250 °C. The sintered parts have very fine tungsten grains embedded in a bulk matrix. With increased copper contents, the tungsten grain size decreases and the microstructural homogeneity of the sintered alloys improves further. The thermal conductivity properties, while a little lower than that of the theoretical value, depend on the copper contents.

► Sol spray drying method is used to prepare nano W–(30–50)Cu composite powders. ► Nano W–Cu composite powders can be sintered to near full density (> 99%TD) at 1200 °C. ► Sintered W–Cu compacts have fine grains and uniform microstructures. ► Sintered W–Cu compacts have excellent thermal conductivity, which is close to the theoretical value.