Bulk Tungsten Fiber-Reinforced Tungsten (WfW) Composites Using Yarn-Based Textile Preforms

Abstract

The use of tungsten fiber-reinforced tungsten composites (Wf/W) has been demonstrated to significantly enhance the mechanical properties of tungsten (W) by incorporating W-fibers into the W-matrix. However, prior research has been restricted by the usage of single fiber-based textile fabrics, consisting of 150 µm warp and 50 µm weft filaments, with limited homogeneity, reproducibility, and mechanical properties in bulk structures due to the rigidity of the 150 µm fibers. To overcome this limitation, two novel textile preforms were developed utilizing radial braided yarns with 7 core- and 16 sleeve filaments (R.B. 16+7) as the warp material. In this study, bulk composites of two different fabric types were produced via a layer-by-layer CVD-process, utilizing single 50 µm filaments (type 1) and R.B. 16+7 yarns (type 2) as weft materials. The produced composites were sectioned into KLST-type specimen based on DIN EN ISO 179-1:2000 using electrical discharge machining (EDM), and subjected to three-point bending tests. Both composites demonstrated enhanced mechanical properties with pseudo-ductile behavior at room temperature and endured over 10,000 load cycles between 50-90 % of their respective maximum load without sample fracture. Composites based on fabric type 1 demonstrated superior manufacturing performance and mechanical properties, a high relative average density (>97 %), and high fiber volume fraction (14-17 %). Furthermore, a novel approach to predict the fatigue behavior of the material under cyclic loading was developed based on the high reproducibility of the mechanical properties of type 1, providing a new benchmark for upscaling endeavors.