高密度タングステン粉
目次
高密度タングステン粉 タングステンは金属粉末の中で最も密度が高く、その固有密度は金に匹敵します。このユニークな特性は、重い粉末のプレスや焼結の方法論を利用して、様々な分野でコンパクトで重量効率の高い部品の高度な設計を可能にします。
概要 タングステン粉
固体の形で19.3 g / cm3の密度で、タングステンは小さなボリュームに巨大な重量をパックします。このおかげで、タングステン粉末は、圧縮されたときに他の材料を使用して達成できない比類のない密度レベルを提供します。高密度タングステン粉末から作られた部品は、要求の厳しい環境で数多くのアプリケーションを見つける。
高密度タングステン粉末を利用する主な促進要因は以下の通り：
- 金やプラチナのような貴金属に似た高い密度
- 鉛やスチールに比べ、使用可能な密度が2倍
- 重くてもコンパクトなサイズと形状が可能
- シンプルな粉末冶金による最終製品へのルート
- 合金元素の混合によるテーラーメイドの特性
- 高価なタングステンのリサイクル性
密度スパン安定器、放射線遮断、慣性、複合材料の加重、振動減衰、部品の小型化などを利用したアプリケーション。
高密度タングステン粉末の種類
すべてのタングステン粉末の品種は、高密度を提供していますが、特定のグレードと組成は、成形および焼結後に最適な密度レベルを付与します：
| タイプ | 説明 | 典型的な密度 |
|---|---|---|
| 純タングステン | 99.95%以上の高純度により、信頼性の高い密度を実現 | ≥18g/cm以上 |
| ドープ・タングステン | Small rare earth oxide additions like Y2O3 improves sintered density | ≥18.5g/cm以上 |
| タングステン-ニッケル-鉄 | Ni-Fe合金化により優れた最終密度を実現 | ≥18g/cm以上 |
| タングステン重合金 | 90-97% W、Ni-Cu-Fe 結合相付き | ≥17.5 g/cm 以上 |
| タングステン複合材料 | 金、タンタル、劣化ウラン等と混合。 | 21g/cmまで |
これらの強化された配合は、純粋なタングステンだけでなく、カスタマイズされた特性の組み合わせまで、高性能の選択肢を広げます。
構成 タングステン粉
高純度タングステン粉末は、99.95%以上のタングステンを含み、不純物はわずかです：
| エレメント | 最大コンテンツ | 役割 |
|---|---|---|
| タングステン（W） | 99.95% | 主成分 |
| カーボン（C） | 100ppm | 穀物成長抑制剤 |
| 酸素 (O) | 100ppm | 表面酸化物 |
| 銅（Cu） | 10 ppm | 残留微量不純物 |
| シリカ（Si） | 20 ppm | 不純物 |
特殊な重合金グレードは、タングステンとともにニッケル、銅、鉄などの合金を意図的に添加し、特性をさらに向上させている。
プロパティ タングステン粉
高密度タングステン粉末は、有用な強度、硬度、熱特性と相まって、極端な密度を誇るニアネットシェイプ部品の製造を可能にします。
物理的性質
| プロパティ | 価値 |
|---|---|
| 密度 | ≥18g/cm以上3。 |
| 融点 | 3380-3410°C |
| 強さ | 最大1000MPa |
| 硬度 | ≥400VPN以上 |
| 熱伝導率 | ∼約175W/(m・K) |
| 熱膨張係数 | ∼4.5 μm/(m-K) |
これらの特性は、タングステンの本質的な原子構造に由来するもので、熱的・機械的完全性を必要とする高密度用途に最適です。
機械的特性
入念な粉末プレスと焼結により、有利な機械的特性が得られる：
| プロパティ | 価値 |
|---|---|
| 硬度 | 最大550VPN |
| 降伏強度 | ∼約900MPa |
| 引張強度 | 最大1000MPa |
| 伸び | ∼約10%～15% |
| 破壊靭性 | ∼約20 MPa√m |
| 疲労強度 | 500 MPa |
ニッケル、鉄などの合金元素は、延性、靭性、加工特性を調整するのに役立つ。
身体的特徴
設計者に有用な高密度タングステン粉末の顕著な物理的属性：
| パラメータ | 価値 | 単位 |
|---|---|---|
| 密度 | 18から19.3 | g/cm3</sup |
| 電気抵抗率 | 5.5 | μΩ-cm |
| 熱伝導率 | 170 | W/(m-K) |
| 融点 | 3410 | °C |
| 沸点 | 5930 | °C |
| 比熱 | 132 | J/(kg-K) |
超高融点と熱伝導性により、極端な温度下でも強度と寸法を維持できる。
製造 タングステン粉
| ステージ | 説明 | Key Points |
|---|---|---|
| 1. Raw Material Acquisition | The process begins with mining tungsten ore, which primarily consists of wolframite and scheelite. | * Tungsten ores are found worldwide, but major producers include China, Peru, and Bolivia. * Mining methods vary depending on the deposit, but common techniques include open-pit and underground mining. * The mined ore undergoes crushing, grinding, and concentration processes to remove impurities and enrich the tungsten content. |
| 2. Chemical Processing | The concentrated ore is then converted into an intermediate chemical compound suitable for further purification and reduction. | * Ammonium paratungstate (APT) is the most widely used intermediate. It’s produced through a series of chemical reactions involving leaching, filtration, and precipitation. * APT offers advantages like high purity and good handling characteristics. * Other intermediate compounds like tungstic acid or tungsten oxides may also be used depending on the specific production process. |
| 3. High-Purity Oxide Production | Further purification steps ensure the removal of remaining impurities and achieve the desired level of tungsten oxide for reduction. | * APT undergoes additional purification steps like recrystallization or solvent extraction to meet the stringent purity requirements for tungsten powder production. * Tungsten oxides like WO3 (tungsten trioxide) or WO2 (tungsten dioxide) are often the final product of this stage. * The choice of oxide and its specific characteristics can influence the final tungsten powder properties. |
| 4. Hydrogen Reduction | The purified tungsten oxide is then reduced to metallic tungsten powder using hydrogen gas in a controlled furnace environment. | * This stage is the heart of tungsten powder production. Hydrogen acts as a reducing agent, taking oxygen away from the tungsten oxide and leaving behind pure tungsten metal particles. * The reduction process occurs in pusher furnaces or rotary furnaces at precisely controlled temperatures (typically between 600°C and 1100°C) and hydrogen gas flow rates. * Careful control of these parameters is crucial for achieving the desired tungsten powder properties like particle size, morphology, and purity. |
| 5. Powder Classification and Finishing | The raw tungsten powder from the reduction furnace undergoes further processing to achieve the final desired characteristics. | * The powder is screened and classified to obtain specific particle size distributions. Different applications require powders with varying particle sizes and morphologies. * Additional processes like milling or granulation may be used to refine the particle size and shape further. * The powder may also be subjected to degassing treatments to remove any residual hydrogen from the reduction process. |
| 6. 品質管理 | Throughout the production process, rigorous quality control measures are implemented to ensure the final tungsten powder meets all the required specifications. | * Chemical analysis determines the elemental composition and purity of the powder. * Particle size distribution and morphology are analyzed using techniques like laser diffraction and electron microscopy. * Other tests may assess properties like density, flowability, and sintering behavior. * Maintaining consistent quality is essential for the performance of tungsten products made from the powder. |
アプリケーション タングステン粉
| カテゴリー | 申し込み | レバレッジ物件 | 例 |
|---|---|---|---|
| Industrial & Manufacturing | Machining & Cutting Tools | 極めて高い硬度、耐摩耗性 | – Drill bits – Milling inserts – End mills – Turning tools |
| Dies & Molds | High melting point, thermal stability | – Extrusion dies for wires and filaments – Hot stamping dies – Plastic injection molding tools | |
| 電極 | 高融点、良好な電気伝導性 | – Inert gas welding (TIG) electrodes – Resistance welding electrodes | |
| Filaments & Heating Elements | 高融点、良好な電気伝導性 | – Incandescent light bulb filaments – Furnace heating elements | |
| 触媒 | High surface area, ability to promote chemical reactions | – Ammonia production catalysts – Hydrocarbon processing catalysts | |
| Pigments & Coatings | High density, opacity to X-rays | – Radiation shielding for medical equipment – X-ray contrast agents | |
| 電気・電子 | 電気接点およびスイッチ | High melting point, good electrical conductivity, arc resistance | – Relay contacts – Circuit breaker contacts – High-voltage switchgear contacts |
| ヒートシンク | 高い熱伝導性 | – Electronic component heat dissipation | |
| Semiconductor Manufacturing | High density, etch resistance | – Tungsten plugs and vias in integrated circuits – Gate electrodes in transistors | |
| 消費財 | スポーツ用品 (Golf Clubs, Fishing Weights) | High density for weight distribution | – Golf club weighting for improved swing – Fishing weights for deeper, faster sinking |
| 振動減衰 | 高密度 | – Dampeners in tennis rackets and archery equipment – Vibration dampers in machinery | |
| Advanced Applications | アディティブ・マニュファクチャリング（3Dプリンティング） | Fine particle size, good flowability | – 3D printed components for aerospace and automotive industries – Medical implants |
| 原子力 | High melting point, neutron absorption | – Control rods in nuclear reactors – Nuclear waste shielding | |
| Military & Defense | 徹甲弾 | High density, extreme hardness |
仕様
高密度タングステン粉末の主要パラメータを定義：
Grades of Tungsten Powder
| Grade Designation | Average Particle Size (Microns) | Purity (Minimum % Tungsten) | アプリケーション |
|---|---|---|---|
| Ultrafine Tungsten Powder | < 1.0 | ≥ 99.95 | – Thermal Spray Coatings for turbine blades and other high-wear applications due to excellent sinterability and flowability. |
| 1.0 – 3.0 | ≥ 99.95 | – Diamond Tools with superior wear resistance and sharpness for cutting and grinding hard materials. | |
| 3.0 – 5.0 | ≥ 99.9 | – Electronic Substrates with minimal impurities for high electrical conductivity and thermal stability in integrated circuits. | |
| Fine Tungsten Powder | 5.0 – 10.0 | ≥ 99.5 | – Cemented Carbide Cutting Tools offering a good balance between hardness, toughness, and fracture resistance for machining various materials. |
| 10.0 – 15.0 | ≥ 99.0 | – Heavy Duty Electrical Contacts requiring high melting point, arc resistance, and electrical conductivity in power switching applications. | |
| 15.0 – 22.0 | ≥ 98.5 | – Electrodes for Tungsten Inert Gas (TIG) Welding due to their ability to produce a stable arc and concentrated heat. | |
| Medium Tungsten Powder | 22.0 – 32.0 | ≥ 98.0 | – Penetrators and Kinetic Energy Projectiles leveraging tungsten’s high density for superior armor penetration. |
| 32.0 – 45.0 | ≥ 97.0 | – Radiation Shielding Materials in medical equipment and nuclear facilities due to tungsten’s ability to absorb X-rays and gamma rays. | |
| Coarse Tungsten Powder | 45.0 – 75.0 | ≥ 96.0 | – Ballast Weights for counterweights and vibration dampeners utilizing tungsten’s high density for compact size and effectiveness. |
| > 75.0 | ≥ 95.0 | – Shot Peening Media for surface strengthening metal components through a cold working process. |
Standards of Tungsten Powder
| プロパティ | 説明 | 重要性 | 代表的な規格 |
|---|---|---|---|
| 純度 | Tungsten powder purity refers to the percentage of tungsten metal (W) present in the powder by weight. Impurities can significantly affect the physical and mechanical properties of tungsten products. | Higher purity generally translates to better performance in applications that rely on properties like electrical conductivity, melting point, and strength. However, extremely high purity may not always be necessary or cost-effective. | – High Purity (99.9% W and above): Used for electronics, filaments, and electrodes where excellent electrical conductivity is crucial. – Standard Purity (99.5% W – 99.9% W): Suitable for various applications like cemented carbide cutting tools, heat sinks, and radiation shielding. – Lower Purity (Below 99.5% W): Used in some specific applications like plastic fillers or as a raw material for further purification. |
| 粒子径と分布 | Particle size refers to the average diameter of individual tungsten particles in the powder. Particle size distribution describes the variation in particle sizes within a powder sample. | Particle size and distribution significantly impact the processing behaviour and final properties of tungsten products. For example, finer particles can offer better sinterability but may be more challenging to handle. | – Micron-Sized Powders (1 – 50 microns): Commonly used for cemented carbide production, thermal spraying, and additive manufacturing. – Submicron Powders (Below 1 micron): Used in applications requiring high surface area, like catalysts and conductive coatings. – Nano Powders (Below 100 nanometers): Emerging area with potential applications in electronics and composite materials. |
| 見かけ密度 | Apparent density represents the weight of tungsten powder per unit volume, considering the spaces between particles. It influences how much powder can be packed into a mold and the final density of the sintered product. | Higher apparent density allows for more efficient use of powder and can lead to denser final products with improved mechanical properties. | – High Density Powders (>10 g/cm³): Used for applications requiring high strength and wear resistance, like cemented carbide tools. – Standard Density Powders (7 – 10 g/cm³): Commonly used for various applications where a balance between density and processing ease is desired. – Low Density Powders (<7 g/cm³): May be used in applications where loose packing or flowability is important, such as some thermal spraying processes. |
| 流動性 | Flowability refers to the ease with which tungsten powder can move and be poured. It is crucial for efficient handling and processing in various applications. | Good flowability ensures smooth powder feeding in machinery and minimizes segregation of different particle sizes within the powder. | – Free-Flowing Powders: Achieved through specific particle size distribution and surface treatments to minimize particle-particle interactions. – 添加物： May be used to improve flowability by reducing friction between particles. |
| 形態学 | Morphology refers to the shape and form of individual tungsten particles. | Particle morphology can influence packing behaviour, sintering characteristics, and the final microstructure of tungsten products. | – 球状粉末： Offer good packing density and flowability. – Angular Powders: May create a more interlocking network during sintering, potentially leading to improved strength. – Dendritic Powders: Can be used for specific applications where their branching structure offers advantages. |
| 酸素含有量 | Oxygen content refers to the amount of oxygen present in the tungsten powder, typically as oxides. Excessive oxygen can affect the final properties of tungsten products. | – Low oxygen content is generally desired for most applications to ensure optimal performance. – Strict oxygen limits are often specified for high-performance applications like electronics and filaments. | |
| タップ密度 | Tap density is a measure of the packing density of tungsten powder achieved through a standardized tapping process. It provides an indirect measure of flowability and apparent density. | – Higher tap density indicates better packing efficiency and can be used as a quality control parameter. | – Industry standards often specify minimum tap density requirements for different tungsten powder grades. |
価格
高密度用途に適したタングステン粉末の代表的な価格：
| グレード | 価格 |
|---|---|
| ウルトラファイン | 1kgあたり$800～$1200 |
| サブミクロン | 1kgあたり$500～$900 |
| ファイン | 1kgあたり$100～$250 |
| ミディアム | 1kgあたり$50～$150 |
| 重合金 | 1kgあたり$40～$100 |
粒径が小さく、純度が高く、特殊なドーパントが使われ、量が少ないとコストが高くなる。リサイクルされたスクラップパウダーの方が安い。
長所と短所
| メリット | デメリット |
|---|---|
| Unmatched High Melting Point: Tungsten powder boasts the highest melting point of any metal, reaching a staggering 3,422°C (6,192°F). This exceptional property allows it to excel in applications exposed to extreme temperatures, like furnace linings, rocket nozzles, and heat shields for spacecraft re-entry. | Costly Investment: Extracting and processing tungsten is a complex procedure, leading to a higher price tag compared to more common metals. This can be a significant hurdle for applications where cost is a major factor. |
| Superior Heat and Electrical Conductivity: Tungsten powder excels in conducting both heat and electricity efficiently. This makes it ideal for applications requiring efficient thermal management, like heat sinks in electronics, or electrical components like filaments in incandescent lamps and electrodes for welding. | Dense and Demanding: Tungsten’s remarkable density, a direct consequence of its tightly packed atomic structure, translates to its powder form as well. This high density can pose challenges during processing. Specialized techniques and equipment might be necessary to handle and shape tungsten powder effectively. |
| Exceptional Wear and Corrosion Resistance: Tungsten powder exhibits outstanding resistance to wear and tear, alongside exceptional corrosion resistance. This makes it perfect for applications requiring exceptional durability in harsh environments, like armor-piercing projectiles, drill bits for tough materials, and components used in chemical processing plants. | Potential Health Risks: Tungsten powder, if inhaled, can irritate the lungs and potentially lead to health complications. Strict safety protocols and proper ventilation are crucial when working with tungsten powder to minimize exposure risks. |
| Tailorable Alloying Potential: Tungsten powder readily forms alloys with various metals, significantly enhancing their properties. This allows engineers to create custom-designed materials with specific combinations of strength, hardness, and heat resistance for applications like high-performance cutting tools and jet engine components. | Limited Global Supply: The primary source of tungsten is geographically concentrated, with China dominating global production. This can lead to supply chain vulnerabilities and potential price fluctuations. |
| 生体適合アプリケーション： Tungsten exhibits good biocompatibility, making its powder form suitable for certain medical applications. For instance, tungsten-based implants can be used for hip replacements due to their exceptional strength and wear resistance. | Specialized Suppliers: Due to the unique properties and potential safety concerns of tungsten powder, sourcing it from reputable and experienced suppliers is essential. These suppliers can provide high-quality, well-characterized powder alongside technical support to ensure safe handling and optimal performance in the desired application. |
| Emerging Applications in 3D Printing: Tungsten powder is finding new applications in the rapidly advancing field of additive manufacturing, also known as 3D printing. Its unique combination of properties makes it suitable for printing high-performance metal parts for aerospace, automotive, and medical industries. | Counterfeit Concerns: The high value of tungsten powder can attract manufacturers of counterfeit products. Working with qualified suppliers with rigorous quality control practices helps mitigate the risk of receiving inferior or impure material. |
サプライヤー
高密度タングステンおよびタングステン合金粉末を世界的に供給している著名な商社やメーカーには以下のものがあります：
| 会社概要 | 所在地 |
|---|---|
| バッファロー・タングステン | 米国 |
| ウルフラム社 | オーストリア |
| プランゼーグループ | ヨーロッパ |
| 中西部タングステン | 米国 |
| 厦門タングステン | 中国 |
| JXニッポン | 日本 |
| 東芝マテリアル | 日本 |
| GTPシェーファー | ドイツ |
これらの企業は、信頼できるワールドクラスのパウダーを商業市場に供給している。
よくあるご質問
| 質問 | 答え |
|---|---|
| 高密度タングステン粉とは？ | 密度が18～19.3g/cm3のタングステン粉末。 |
| 高密度タングステン粉の製造方法は？ | 精製された酸化タングステンの還元と特殊な粉砕を組み合わせ、希望する粒子径にする。 |
| 高密度タングステン粉末は何に使われるのか？ | カウンターウェイト、放射線シールド、バラスト、ウェイトコンパウンド、制振部品などの製造 |
| 高密度パウダーにはどのような種類がありますか？ | 純タングステン、希土類酸化物をドープしたタングステン、タングステン-ニッケル-鉄合金、タングステン重合金など。 |
| 高密度タングステン粉末の利点は何ですか？ | 他の粉体とは比較にならないコンパクトな体積で極めて高い密度を実現、複雑な部品へのネットシェイプ加工が可能 |
| タングステンパウダーを使用する際の限界は？ | タングステンカーバイドよりも硬度が比較的低く、靭性と延性が限られているため、加工上の課題がある。 |
| 高密度タングステンパウダーは、鉛のような従来の高密度材料と比較してどうですか？ | 有毒な鉛よりも安全、鉛よりも融点が高い、同程度の密度の貴金属に対して経済的な価格 |
概要
元素金属の中でも並外れた密度を持つ高純度タングステン粉末は、以前には実現不可能だったコンパクトなプロファイルを必要とする重量重視のアプリケーションのためのユニークな機能を設計者に提供します。粉末の製造、プレス、焼結、二次加工の進歩は、より広い使用のロックを解除脆性の制限を克服する。ブレンドと合金は、高密度が強度、硬度、熱血統と決定的に結合する要求の厳しい電気、原子力、自動車、航空宇宙分野での物理的特性の追加調整を提供します。
持続可能な供給源が信頼できるグローバルサプライチェーンを支えているため、設計者は現在、タングステン粉末の極限密度を利用し、重さとコンパクトさが一体となって価値を生み出す各産業の精密工学的機能性を追求しています。タングステンの戦略的重要性が高まるにつれ、大手メーカーは今後10年で、20g/cm3を超える密度のしきい値を超えることを追求するでしょう。
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MET3DP Technology Co., LTDは、中国青島に本社を置く積層造形ソリューションのリーディングプロバイダーです。弊社は3Dプリンティング装置と工業用途の高性能金属粉末を専門としています。
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