Sustainable processing of tungsten heavy alloys via ultrasonic recycling and aluminum addition: microstructure and mechanical property optimization
Abstract This study presents the sustainable preparation and characterization of a novel Class 2 tungsten heavy alloy (WHA) reinforced with varying aluminum (Al) contents (0–4 wt%). High-purity recycled tungsten powder was produced via ultrasonic-assisted acidic leaching and alloyed with nickel (Ni)...
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| Format: | Article |
| Language: | English |
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Springer
2025-06-01
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| Series: | Discover Materials |
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| Online Access: | https://doi.org/10.1007/s43939-025-00283-x |
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| author | H. M. Zidan Ahmed I. Z. Farahat Nora M. Hilal Mona F. Amin Omayma A. El-Kady |
| author_facet | H. M. Zidan Ahmed I. Z. Farahat Nora M. Hilal Mona F. Amin Omayma A. El-Kady |
| author_sort | H. M. Zidan |
| collection | DOAJ |
| description | Abstract This study presents the sustainable preparation and characterization of a novel Class 2 tungsten heavy alloy (WHA) reinforced with varying aluminum (Al) contents (0–4 wt%). High-purity recycled tungsten powder was produced via ultrasonic-assisted acidic leaching and alloyed with nickel (Ni) and iron (Fe) using the powder metallurgy technique. X-ray diffraction (XRD) and scanning electron microscopy (SEM) analyses confirmed phase evolution and significant microstructural refinement. The average tungsten grain size decreased from 17.9 μm (0% Al) to 9.8 μm (4% Al). Density measurements showed that porosity decreased notably at 3% Al content. The 2% Al alloy achieved the highest compressive strength of 2310.8 MPa and excellent ductility, while the 4% Al alloy exhibited superior hardness (36.1% increase) and wear resistance (49.5% improvement). True stress–strain analysis revealed enhanced elastic limits and work-hardening behavior at intermediate Al additions. Moreover, bearing zone percentages, determined via Abbott–Firestone analysis, showed a consistent increase with higher Al contents, indicating improved load-bearing surface characteristics. These findings demonstrate that controlled aluminum alloying significantly enhances densification, microstructure uniformity, and mechanical performance, positioning recycled WHAs as promising candidates for high-stress industrial applications. |
| format | Article |
| id | doaj-art-8c6ed40407eb4950b0c6f228e8b9e303 |
| institution | DOAJ |
| issn | 2730-7727 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | Springer |
| record_format | Article |
| series | Discover Materials |
| spelling | doaj-art-8c6ed40407eb4950b0c6f228e8b9e3032025-08-20T03:10:18ZengSpringerDiscover Materials2730-77272025-06-015111810.1007/s43939-025-00283-xSustainable processing of tungsten heavy alloys via ultrasonic recycling and aluminum addition: microstructure and mechanical property optimizationH. M. Zidan0Ahmed I. Z. Farahat1Nora M. Hilal2Mona F. Amin3Omayma A. El-Kady4Powder Technology Department, Central Metallurgical R&D Institute (CMRDI)Plastic Deformation Department, Central Metallurgical R&D Institute (CMRDI)Department of Chemistry, Faculty of Science, Al Azhar University (Girls)Department of Chemistry, Faculty of Science, Al Azhar University (Girls)Powder Technology Department, Central Metallurgical R&D Institute (CMRDI)Abstract This study presents the sustainable preparation and characterization of a novel Class 2 tungsten heavy alloy (WHA) reinforced with varying aluminum (Al) contents (0–4 wt%). High-purity recycled tungsten powder was produced via ultrasonic-assisted acidic leaching and alloyed with nickel (Ni) and iron (Fe) using the powder metallurgy technique. X-ray diffraction (XRD) and scanning electron microscopy (SEM) analyses confirmed phase evolution and significant microstructural refinement. The average tungsten grain size decreased from 17.9 μm (0% Al) to 9.8 μm (4% Al). Density measurements showed that porosity decreased notably at 3% Al content. The 2% Al alloy achieved the highest compressive strength of 2310.8 MPa and excellent ductility, while the 4% Al alloy exhibited superior hardness (36.1% increase) and wear resistance (49.5% improvement). True stress–strain analysis revealed enhanced elastic limits and work-hardening behavior at intermediate Al additions. Moreover, bearing zone percentages, determined via Abbott–Firestone analysis, showed a consistent increase with higher Al contents, indicating improved load-bearing surface characteristics. These findings demonstrate that controlled aluminum alloying significantly enhances densification, microstructure uniformity, and mechanical performance, positioning recycled WHAs as promising candidates for high-stress industrial applications.https://doi.org/10.1007/s43939-025-00283-xRecycling of WHAsTungsten heavy alloyAluminumAbbott FirestonePowder Metallurgy |
| spellingShingle | H. M. Zidan Ahmed I. Z. Farahat Nora M. Hilal Mona F. Amin Omayma A. El-Kady Sustainable processing of tungsten heavy alloys via ultrasonic recycling and aluminum addition: microstructure and mechanical property optimization Discover Materials Recycling of WHAs Tungsten heavy alloy Aluminum Abbott Firestone Powder Metallurgy |
| title | Sustainable processing of tungsten heavy alloys via ultrasonic recycling and aluminum addition: microstructure and mechanical property optimization |
| title_full | Sustainable processing of tungsten heavy alloys via ultrasonic recycling and aluminum addition: microstructure and mechanical property optimization |
| title_fullStr | Sustainable processing of tungsten heavy alloys via ultrasonic recycling and aluminum addition: microstructure and mechanical property optimization |
| title_full_unstemmed | Sustainable processing of tungsten heavy alloys via ultrasonic recycling and aluminum addition: microstructure and mechanical property optimization |
| title_short | Sustainable processing of tungsten heavy alloys via ultrasonic recycling and aluminum addition: microstructure and mechanical property optimization |
| title_sort | sustainable processing of tungsten heavy alloys via ultrasonic recycling and aluminum addition microstructure and mechanical property optimization |
| topic | Recycling of WHAs Tungsten heavy alloy Aluminum Abbott Firestone Powder Metallurgy |
| url | https://doi.org/10.1007/s43939-025-00283-x |
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