Applications of Copper Tungsten Composites

T&D composite materials, comprising tungsten or tungsten carbide and copper or silver, are produced through a precise manufacturing process. This involves pressing the refractory material (tungsten or tungsten carbide), sintering the compact at high temperatures, and subsequently infiltrating it with copper or silver, all conducted under stringent control conditions. The outcome is a durable material with excellent arc and wear resistance, impressive physical properties under elevated temperatures, and commendable electrical and thermal conductivity.

The composition influences the mechanical and physical characteristics, wherein the thermal and electrical conductivity rises with higher levels of copper and silver, while increased amounts of tungsten or tungsten carbide enhance hardness, strength, and resistance to mechanical wear. The choice of material depends on the specific application.

Resistance Welding

The excellent physical and mechanical characteristics, along with notable thermal and electrical conductivity, render refractory metal composites highly appropriate for applications such as die inserts and electrode facings, as well as for use in flash and butt welding dies and hot upsetting. Additionally, these materials can address challenges related to heat balance.

Heat Sinks

T&D Materials, Ltd developed Thermitech for widespread application in thermal mounting plates, chip carriers, flanges, and frames for high-power electronic devices. As a copper tungsten material, it’s a composite, that combines the thermal benefits of copper with the exceptionally low expansion properties of tungsten.

The combination of these two materials yields thermal expansion properties comparable to silicon carbide, aluminum oxide, and beryllium oxide, commonly employed in chips and substrates. Due to its effective thermal conductivity and expansion characteristics, it performs well in densely populated circuits.

Electrical Contacts

T&D Materials engineered Elecon materials for applications in oil-filled devices, air and gas circuit breakers, contactors, and high-voltage switchgear. Various typical uses include:

• Arcing contacts and plates
• Arc runners
• Current carrying members
• Blade facings

Our materials undergo a process of pressing, sintering, and infiltrating for production. Every manufacturing phase, from the initial powder to the final product, is meticulously controlled, monitored, and approved by our Quality Assurance team. Following production, each manufactured lot is thoroughly examined for conductivity, density, and hardness before shipment. Comprehensive records of this information are maintained and stored, and these records are also provided with the parts or materials upon request.

EDM and ECM

T&D Materials’ tungsten composites find global applications as electrodes in Electrical Discharge Machining (EDM) and Electrochemical Machining (ECM). The manufacturing process consists of pressing, sintering, and infiltrating, using virgin powders to ensure a consistently homogeneous material with high and uniform burning rates. Copper tungsten is specifically utilized in plunger/sinker applications that demand intricate definition, particularly in tungsten carbide.

Composites Typical Properties