Synthesis and Processing Techniques of Tungsten Copper Composite Powders for Electrical Contact Materials A Review

Abstract

This review presents a general survey on synthesis and processing techniques of tungsten copper (W-Cu) composite powders for achieving electrical contact materials for power engineering applications. Several chemical and mechano-chemical synthesis methods for obtaining W-Cu composite powders in nano or micro scales from various W and Cu metal salt precursors combined with hydrogen reduction or nitridation-denitridation processes are reported along with powder metallurgy (PM) techniques employed in manufacturing W-Cu electrical contact materials. The main advantages and disadvantages of synthesis and processing techniques are summarized, too. The interdepencies among the properties of starting materials and final products in relation with synthesis and processing parameters are highlighted. The review reveals that the development of W-Cu advanced materials with improved properties and scale-up potential is of a great interest in practical applications related to materials science and engineering field.

Graphene and its derivative reinforced tungsten–copper composites for electrical contact applications: A review

“…W yields the highest melting point (3410°C) among metals, as well as very high density, high hardness, and good wear resistance, while Cu has lower melting point (1083°C) than W but superior conductivities to those of W (Table 1), 1,2,11 along with high ductility and good malleability. By considering also the insignificant solubility (≤10 À3 wt.%) 1,2,11 and very poor wettability between W and Cu, the researches over the years were focused on the development of proper approaches and innovative technologies to enhance the technical characteristics and functional behavior of this class of composites. The major differences existent in W and Cu characteristics (Table 1) are the reasons why these composites are manufactured by various powder metallurgy (PM) techniques.…”

“…The major differences existent in W and Cu characteristics (Table 1) are the reasons why these composites are manufactured by various powder metallurgy (PM) techniques. Classical PM techniques include (i) pressing, sintering, and infiltration (PSI) of porous W-based skeletons with Cu-liquid phase [1][2][3][4][5][6][7][8][9][10][11] and (ii) hot pressing, and sintering (HPS) [12][13][14] that are realized at high sintering temperatures with long-duration processes of over 4 h. On the contrary, unconventional and fast PM techniques comprise spark plasma sintering (SPS) technique [1][2][3]5,[15][16][17][18] and microwave sintering (MWS) [19][20][21] at reduced sintering temperatures and much shorter duration processes (mostly of maximum 1 h) without considerable grain size growth of the sintered materials that exhibit improved properties comparatively with the materials obtained by classical PM techniques.…”

“…Among the key strategies to obtain enhanced characteristics of W-Cu-based composites was targeted the improvement of sinterability and bonding strength among W and Cu matrix through small amounts of additives like transition elements (Ni, Co, Fe, Cr, Zn, Ag, etc. ), [1][2][3][5][6][7][8]11 other metallic elements (i.e., Sn), 22 lanthanide oxides (i.e., CeO 2 , La 2 O 3 , Y 2 O 3 ) 1,18 and secondary metallic carbide phases (i.e., WC, TiC, and HfC). 9,23,24 Composites with a weight content of about 60-85% W, balance % Cu should have very good switching behavior, including high resistance to arc erosion and wear, good arc stability, high temperature, and mechanical strength, whereas high conductivities should be kept along with long lifetime in service.…”

High anti-arc erosion performance of the Al2O3 reinforced Cu@W composites for high voltage circuit-breaker contacts

“…Advanced fabrication technology and adding reinforcement elements are effective strategies to improve the performance of electrical contact materials [7][8][9][10][11]. Infiltration technology has been adopted for decades as the mainstream method for CuW contacts manufacturing.…”

“…An ideal contact material should possess the following merits: appropriate hardness, high electrical conductivity, high thermal conductivity, low contact resistance, and high resistance against electrical arc erosion.Copper-tungsten (CuW) alloy is a pseudo-binary phase composite conventionally used in manufacturing circuit-breaker contacts [6]. The CuW alloy enjoys the benefits held by Cu and W elements, such as maintaining favorable mechanical strength, high electrical arc erosion, and welding resistance due to the presence of W, while keeping excellent electrical and thermal conductivity as a result of the presence of Cu.Advanced fabrication technology and adding reinforcement elements are effective strategies to improve the performance of electrical contact materials [7][8][9][10][11]. Infiltration technology has been adopted for decades as the mainstream method for CuW contacts manufacturing.…”