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Synthesis, structure and mechanical properties of ice-templated tungsten foams

Published online by Cambridge University Press:  04 March 2016

André Röthlisberger ,
Sandra Häberli ,
Ralph Spolenak  and
David C. Dunand
André Röthlisberger
Affiliation:
Mechanical Integrity of Energy Systems, Swiss Federal Laboratories for Materials Science and Technology, EMPA, CH-8600 Dübendorf, Switzerland; and Laboratory for Nanometallurgy, Department of Materials, ETH Zürich, CH-8093 Zürich, Switzerland
Sandra Häberli
Affiliation:
Laboratory for Nanometallurgy, Department of Materials, ETH Zürich, CH-8093 Zürich, Switzerland
Ralph Spolenak
Affiliation:
Laboratory for Nanometallurgy, Department of Materials, ETH Zürich, CH-8093 Zürich, Switzerland
David C. Dunand*
Affiliation:
Department of Materials Science and Engineering, Northwestern University, Evanston, Illinois 60208, USA
*
a)Address all correspondence to this author. e-mail: [email protected]
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Abstract

Tungsten foams with directional, controlled porosity were created by directional freeze-casting of aqueous WO3 powder slurries, subsequent freeze-drying by ice sublimation, followed by reduction and sintering under flowing hydrogen gas to form metallic tungsten. Addition of 0.51 wt% NiO to the WO3 slurry improved the densification of tungsten cell walls significantly at sintering temperatures above 1250 °C, yielding densely sintered W–0.5 wt% Ni walls with a small fraction of closed porosity (<5%). Slurries with powder volume fractions of 15–35 vol% were solidified and upon reduction and sintering the open porosity ranges from 27–66% following a linear relation with slurry solid volume fraction. By varying casting temperature and powder volume fraction, the wall thickness of the tungsten foams was controlled in the range of 10–50 µm. Uniaxial compressive testing at 25 and 400 °C, below and above the brittle-to-ductile-transition temperature of W, yields compressive strength values of 70–96 MPa (25 °C) and 92–130 MPa (400 °C).

Keywords

porous materialfreeze-castingfreeze-dryingrefractory metals
Type
Articles
Information
Journal of Materials Research , Volume 31 , Issue 6 , 28 March 2016 , pp. 753 - 764
Copyright
Copyright © Materials Research Society 2016 

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