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materials

Review Effect of Rare Earth (Y, La) and Metals (Mo, Ta, Re) to Improve the Mechanical Properties of W–Ni–Fe —A Review

Senthilnathan Natarajan 1, Venkatachalam Gopalan 2, Raja Annamalai Arunjunai Rajan 3 and Chun-Ping Jen 4,*

1 School of Mechanical , Vellore Institute of Technology (VIT), Vellore 632014, India; [email protected] 2 Centre for Innovation and Product Development, Vellore Institute of Technology (VIT), Chennai 600127, India; [email protected] 3 Centre for Innovative Manufacturing Research, Vellore Institute of Technology (VIT), Vellore 632014, India; [email protected] 4 Department of Mechanical Engineering and Advanced Institute of Manufacturing for High-Tech Innovations, National Chung Cheng University, Chia-Yi 62102, Taiwan * Correspondence: [email protected]

Abstract: heavy alloys are two- matrix composites that include W–Ni–Fe and W–Ni–Cu. The significant feature of these alloys is their ability to acquire both strength and . In order to improve the mechanical properties of the basic alloy and to limit or avoid the need for post-processing techniques, other elements are doped with the alloy and performance studies are   carried out. This work focuses on the developments through the years in improving the performance of the classical tungsten heavy alloy of W–Ni–Fe through doping of other elements. The influence of Citation: Natarajan, S.; Gopalan, V.; the percentage addition of rare earth elements of yttrium, lanthanum, and their and refractory Rajan, R.A.A.; Jen, C.-P. Effect of Rare Earth Metals (Y, La) and such as , , and on the mechanical properties of the heavy alloy Metals (Mo, Ta, Re) to Improve the is critically analyzed. Based on the microstructural and property evaluation, the effects of adding Mechanical Properties of W–Ni–Fe the elements at various proportions are discussed. The addition of molybdenum and rhenium to Alloy—A Review. Materials 2021, 14, the heavy alloy gives good strength and ductility. The oxides of yttrium, when added in a small 1660. https://doi.org/10.3390/ma quantity, help to reduce the tungsten’s grain size and obtain good tensile and compressive strengths 14071660 at high temperatures.

Academic Editor: Ana Senos Keywords: tungsten heavy alloy; refractory metal; rare earth element; microstructure; mechanical properties Received: 9 February 2021 Accepted: 19 March 2021 Published: 28 March 2021 1. Introduction Publisher’s Note: MDPI stays neutral with regard to jurisdictional claims in Tungsten, as a metal, is unique due to its high , high , good published maps and institutional affil- , and high elastic modulus [1]. In the early days of its application, iations. tungsten was used in incandescent lamps in the mode of coils and . The applica- tion widened with the advent of new production and processing methods. The high melting point of tungsten makes it a premium element in plasma-facing components in reactors [2–5], electrical contacts [6], electron emitters, welding , sputtering tar- gets, and heat sinks [7]. The other major feature of tungsten is its high density (19.3 g/cm3), Copyright: © 2021 by the authors. Licensee MDPI, Basel, Switzerland. which is a needed property in radiation shielding applications [8,9]. One major drawback This article is an open access article of tungsten is its property of brittleness below the ductile-to-brittle transition temperature. distributed under the terms and This temperature varies depending on the preparation of tungsten. The poor ductility conditions of the Creative Commons of tungsten poses a greater challenge in its performance in demanding applications. To Attribution (CC BY) license (https:// improve the workability of tungsten, it is alloyed with other elements. The alloying ad- creativecommons.org/licenses/by/ ditions are done to improve the dislocation mobility of atoms, to reduce the segregation 4.0/). of impurities along the grain boundaries, to refine the microstructure, and, thereby, to

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improve the strength and ductility of tungsten [10]. Over the years, alloying elements such as rhenium [11,12], [11], , tantalum [13], molybdenum [14], [15], and oxides of lanthanum and yttria [16–18] have been investigated with tungsten. The application of tungsten widened with the advent of tungsten heavy alloys (WHAs). The classical heavy alloy consists of tungsten-- as one and tungsten-nickel- copper as the other. The add-ons with tungsten help to maintain a distinctive combination of strength and ductility of the alloy. They are generally two-phase composites with a tungsten phase and a binder element phase [19]. The heavy alloys find application as counterweights, radiation shields, rotating inertia members like gyroscopes, semiconductor substrates, collimators, machining tools, kinetic energy penetrators, and fragmentation de- vices in defense [20]. Pure tungsten requires a very high temperature, in the range of 1600 to 2000 ◦C, depending upon the tungsten particle size and the sintering method to get fully densified [21–23]. To overcome this difficulty in sintering and to introduce a duc- tile phase into the alloy, elements with a lower melting point and having preferably good solubility with tungsten are mixed with the . The percentage of tungsten in the heavy alloy generally varies from 80 to 98 wt% [24,25]. The higher percentage of tungsten helps to maintain a higher density of the alloy. The powder technique is primar- ily used to fabricate tungsten heavy alloys [26,27]. In a general process, the powders are mixed in a mixer or a ball mill to obtain a homogeneous mixture followed by compaction at a desired pressure in a press to obtain a green compact with sufficient strength. Further, the compact is sintered in a sintering furnace at a particular temperature and dwell time to get the final product with good density and strength [28]. During liquid phase sintering of W–Ni–Fe, the element with the lower melting point melts and the tungsten forms a solution with nickel and iron and, thereby, particle rearrangement takes place [29,30]. The addition of Ni improves the grain boundary activation of tungsten particles. The solubility of tungsten at a temperature of 1480 ◦C is about 45 and 30 wt% with nickel and iron, respectively [31]. In the liquid phase sintering of W–Ni–Fe, the alloy specimen may be subjected to shape distortion if the quantity of liquid phase is high. Hence, it is suggested to keep the liquid volume below 20% [32,33]. The iron and nickel are mutually soluble over a wide temperature range. The tungsten grains get dispersed in the face-centered cubic (FCC) matrix of Ni–Fe–W. The small grains dissolve in the matrix and, after saturation, get reprecipitated on coarser W grains. This process to microstructural changes and densification of the alloy. The addition of copper with tungsten does not provide good densification as both are mutually insoluble. However, with nickel as the main additive, the combination of W–Ni–Cu is able to produce a fully dense alloy [34,35]. Over the years, different sintering methods have been used to consolidate W–Ni–Fe and W–Ni–Cu heavy alloys. The sintering temperature for the liquid phase ranges from 1450 to 1500 ◦C. The conventional sintering method requires more sintering time to get a fully dense alloy. Using other sintering techniques, like microwave sintering and spark plasma sintering, the sintering time was reduced significantly. In the overall processing time, an 80% reduction was observed with the use of microwave sintering compared with the conventional method [36]. Spark plasma sintering is a unique technique where a pulsed DC current is supplied to the powder mixture simultaneously with the desired pressure to achieve a fully dense alloy in a significantly shorter sintering cycle [37]. It was also reported that in spark plasma sintering (SPS), film formation was reduced and segregation of impurities was restricted due to surface activation of the powder particles [38]. Powder injection molding (PIM) is another processing method successfully used to produce tungsten heavy alloys [39,40]. Initially, the metal powders are mixed with an organic binder, usually a thermoplastic polymer, at a specific temperature and pressure and the resultant is known as the feedstock. The feedstock is then fed into the injection molding unit for processing to produce the mold, followed by debinding and sintering. It is understood that the PIM combines the metallurgy technique with the injection molding process. It is used for mass production of parts to produce dense and complex near-net-shape parts. The major challenge in the process is to maintain Materials 2021, 14, 1660 3 of 20

a defect-free shape of the product by properly controlling the debinding process. In recent years, new processing methods like laser melting deposition (LMD) [41,42] and selective laser melting (SLM) [43,44] have been attempted to produce tungsten heavy alloys. These additive manufacturing techniques are used to fabricate near-net-shaped parts of high complexity. The mechanical properties of tungsten heavy alloys depend on various factors such as tungsten grain size, contiguity, matrix volume fraction, tungsten dissolution in the matrix phase, segregation of impurities on the tungsten matrix interface, intermetallic precipitation, and residual porosity [45–47]. The desired properties of strength and can be obtained through swaging and heat treatment after sintering. However, the objective of obtaining near-net-shape components using the technique without the need for further processing has not been met. The research over the years has been focused on improving the properties of the heavy alloy by avoiding thermo-mechanical treatments. One of the methods was to add other elements to the W–Ni–Fe to improve the strength of the alloy. Although studies are available on tungsten heavy alloys that discuss the processing methods and improvements in general, the specific analysis of the effects of alloying elements and their critical review is limited. This work investigates the alloying approaches to the elements rhenium, tantalum, and molybdenum and the oxide dispersion of yttrium and lanthanum on W–Ni–Fe alloys. The correlation between the microstructural evolution through different processing conditions and the mechanical properties of strength and ductility is examined. An understanding of the effects of alloying these elements in different proportions will help us to optimize the process of designing materials for specific requirements.

2. Effect of Rhenium and Tantalum on W–Ni–Fe The investigations on the characterization of tungsten heavy alloy with additions of Rhenium (Re) and Tantalum (Ta) are limited. A positive outcome was observed in the case of the mechanical properties of the alloy with the addition of Rhenium in the range of 0.8–1.0 wt%. Re, in general, possesses good strength and toughness. It has a high melting point of 3182 ◦C but has good solubility in body-centered cubic (BCC) and FCC structures, leading to solid solution strengthening of the matrix and alloy. Earlier investigations by Bose and German [48,49] with Re addition revealed a good refinement of tungsten grains with an increase in the hardness and strength. However, there was a slight reduction in the percentage of elongation compared with the unalloyed system. The influence of 0.2 to 1 wt% of Re on 93W–4.9Ni–2.1Fe was investigated by Wensheng et al. [50]. The mixture was subjected to ball milling for 50 h, which resulted in a fine-grained alloy, followed by compaction and sintering at 1490 ◦C for a of 90 min. The relative density and the tensile strength of the alloy showed an increasing trend with an increase in the amount of Re in the alloy as shown in Figure1. The elongation was reduced as observed in the previous investigation [51]. However, the amount of reduction was only 15% with an increase in Re of up to 0.6 wt%. With a further increase in the additive, the rate of reduction in elongation increased. The strength of the alloy depends on the amount of rhenium dissolution in the matrix. If some of the rhenium particles are undissolved, they settle around the tungsten grains, leading to a decline in the properties of the alloy. High-energy milling of alloy powders was found to reduce the inhomogeneity in the alloy [49,51]. A novel method of producing the alloy was used by Ravi Kiran et al. [51]. The tungsten powder was mixed with 1 wt% of rhenium particles in a ball mill for 5 h. The milled powders were then mixed with nickel and iron particles and again milled for 48 h. The composition considered for the analysis was 89W–7Ni–3Fe–1Re. The sintering was done for 120 min at 1480 ◦C under a atmosphere followed by heat treatment and quenching. The grain size got refined in the milled and sintered alloy to 18 microns compared with the 25 microns obtained with a conventionally sintered alloy without the milling process. However, the matrix volume fraction and tungsten dissolution in the matrix phase did Materials 2021, 14, x FOR PEER REVIEW 4 of 22

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not change significantly. However, the contiguity was reduced to 0.27 from 0.36 [51]. The Materials 2021, 14, x FOR PEER REVIEW microstructural parameters are shown in Table1. The theory of undissolved rhenium 4 of 22 particles is visible in the microstructure of the conventionally sintered alloy as shown in Figure2. The milled alloy exhibited relatively good tensile strength. The mechanical properties obtained through various investigations are presented in Table2.

Figure 1. Variation in (a) tensile strength and (b) elongation with Re addition [50]. Reproduced with permission from Liu et al, Bulletin of ; published by Springer, 2008.

The strength of the alloy depends on the amount of rhenium dissolution in the ma- trix. If some of the rhenium particles are undissolved, they settle around the tungsten grains, leading to a decline in the properties of the alloy. High-energy milling of alloy powders was found to reduce the inhomogeneity in the alloy [49,51]. A novel method of producing the alloy was used by Ravi Kiran et al [51]. The tungsten powder was mixed with 1 wt% of rhenium particles in a ball mill for 5 h. The milled powders were then mixed with nickel and iron particles and again milled for 48 h. The composition consid- ered for the analysis was 89W–7Ni–3Fe–1Re. The sintering was done for 120 min at 1480 Figure 1. Variation in (a) tensile°C under strength a hydrogen and (b) elongation atmosphere with Re followed addition by [50 heat]. Reproduced treatment with and permission oil quenching. from The Figure 1. Variation in (a) tensile strength and (b) elongation with Re addition [50]. Reproduced with permission from Liu Liu et al, Bulletin of Materialsgrain Science; size publishedgot refined by in Springer, the milled 2008. and sintered alloy to 18 microns compared with the 25 et al, Bulletin of Materials Science; published by Springer, 2008. microns obtained with a conventionally sintered alloy without the milling process. TableHowever, 1. Microstructural the matrix parametersvolume fraction of the Reand added tungsten to the tungstendissolution heavy in alloythe matrix [51]. phase did The strength of the alloy depends on the amount of rhenium dissolution in the ma- not change significantly. However, the contiguity was reduced to 0.27 from 0.36 [51]. The Tungsten Grain Matrix Volume Dihedral trix. If Alloysome Type of the rhenium particles are undissolved,Contiguity they settle around the tungsten microstructural parametersSize (µ m) are shownFraction in Table (%) 1. The theory of undissolvedAngle rhenium (◦) grainsparticles, leading is visible to a indecline the microstructure in the properties of the conventionallyof the alloy. High sintered-energy alloy millingas shown of in alloy powdersConventional was found to reduce 25 ± 11 the inhomogeneity 17 ± 3 in the 0.36 alloy± 0.07 [49,51]. A novel 58 ± 1 method of FigureMilled 2. The milled alloy 18 ± 6 exhibited relatively 19 ± 1 good ten 0.27sile± strength.0.06 The 42 mechanical± 2 producingproperties the obtained alloy wa throughs used various by Ravi investigations Kiran et al are[51] presented. The tungs in Tableten powder 2. was mixed with 1 wt% of rhenium particles in a ball mill for 5 h. The milled powders were then mixed with nickel and iron particles and again milled for 48 h. The composition consid- ered for the analysis was 89W–7Ni–3Fe–1Re. The sintering was done for 120 min at 1480 °C under a hydrogen atmosphere followed by heat treatment and oil quenching. The grain size got refined in the milled and sintered alloy to 18 microns compared with the 25 microns obtained with a conventionally sintered alloy without the milling process. However, the matrix volume fraction and tungsten dissolution in the matrix phase did not change significantly. However, the contiguity was reduced to 0.27 from 0.36 [51]. The microstructural parameters are shown in Table 1. The theory of undissolved rhenium particles is visible in the microstructure of the conventionally sintered alloy as shown in Figure 2. The milled alloy exhibited relatively good tensile strength. The mechanical properties obtained through various investigations are presented in Table 2.

Figure 2. a Figure 2. ((a)) SEMSEM micrographmicrograph showingshowing thethe presencepresence ofof undissolvedundissolved rheniumrhenium particlesparticles inin thethe conventionallyconventionally sinteredsintered alloyalloy withoutwithout millingmilling and and ( b(b) Energy-Dispersive) Energy-Dispersive Spectroscopy Spectroscopy pattern pattern of rheniumof rhenium (Re) (Re) particle particle [51 ].[51]. Reproduced Reproduced with with permission permis- fromsion from Ravi KiranRavi Kiran et al., et Journal al., Journal of Alloys of Alloys and Compounds; and Compounds; published published by Elsevier, by Elsevier, 2017. 2017

Tantalum is a bcc-structured refractory material that has total solubility for tung-

sten and good dissolution in the matrix [52]. The investigations of tantalum-doped tung- sten [53,54] revealed good refinement of tungsten grains. However, the presence of residual porosity and the brittleness of the structure at low and moderate temperatures limit the use of Ta with a tungsten alloy. A 5 wt% of Ta was added to the tungsten heavy alloy of 85W– 7Ni–3Fe and sintered at a temperature of 1500 ◦C for 30 min in a hydrogen environment followed by heat treatment at 1100 ◦C for one hour. The microstructural difference between

Figure 2. (a) SEM micrograph showing the presence of undissolved rhenium particles in the conventionally sintered alloy without milling and (b) Energy-Dispersive Spectroscopy pattern of rhenium (Re) particle [51]. Reproduced with permis- sion from Ravi Kiran et al., Journal of Alloys and Compounds; published by Elsevier, 2017

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Materials 2021, 14, x FOR PEER REVIEW 5 of 22 the alloy with tantalum and the alloy without tantalum was clearly visible as shown in Figure3. The tantalum-doped alloy offers a refined grain size, but with the presence of some porosity. Although a high tensile strength (1025 MPa) is possible with this alloy, there Tableis a significant 1. Microstructural drop in parameters the elongation of the percentage, Re added to which the tungsten is only heav 3% comparedy alloy [51]. with the 31% obtained in undoped alloy. Tungsten Grain Matrix Volume Alloy Type Contiguity Dihedral Angle (o) Size (µm) Fraction (%) Table 2. Mechanical properties of the rhenium and tantalum added to the tungsten heavy alloy of W–Ni–Fe. Conventional 25 ± 11 17 ± 3 0.36 ± 0.07 58 ± 1 Milled 18 ± 6 Hardness 19 Tensile± 1 Strength0.27 ± 0.06Elongation 42 ± 2 Alloy Sintering Process Reference (HRA) (MPa) (%) Tantalum is a bcc-structured refractory material that has total solubility for tungsten ◦ W–8Ni–2Fe–6Re Sinteringand go atod 1500 dissolutionC for 60 minin the matrix —[52]. The investigations 1180 of tantalum 13-doped tung [49] sten W–4.9Ni–2.1Fe — 997 26.4 Ball[53,54 milled] revealed for 50 h Sintered good refinement at of tungsten grains. However, the presence of residual W–4.9Ni–2.1Fe–0.2Re — 1050 26 [50] 1490 ◦C for 90 min W–4.9Ni–2.1Fe–0.4Reporosity and the brittleness of the structure — at low 1090 and moderate temperatures 25 limit the Sinteringuse of atTa 1480 with◦C a for tungsten 120 min alloy. A 5 wt% of Ta was added to the tungsten heavy alloy of W–7Ni–3Fe–1Re — 890 14 followed85W–7Ni by–3Fe heat and treatment sintered at a temperature of 1500 °C for 30 min in a hydrogen[51 ]envi- W–Reronment milled for followed 5 h followed by byheat 48 treatment h at 1100 °C for one hour. The microstructural differ- of milling of the whole mixture. W–7Ni–3Fe–1Re ence between◦ the alloy with tantalum— and the alloy 952 without tantalum 23 was clearly visible Sinteringas shown at 1480 in FigureC for 120 3. minThe tantalum-doped alloy offers a refined grain size, but with the followed by heat treatment presence of some porosity. Although a high tensile strength (1025 MPa) is possible with W–7Ni–3Fe Sintering at 1500 ◦C for 30 min and 62.8 925 31 [52] W–7Ni–3Fe–5Taheat treatedthis alloy, at 1100 there◦C for is one a significant hour drop 69 in the elongation 1025 percentage 3, which is only 3% compared with the 31% obtained in undoped alloy.

Figure 3. Microstructure ofof ((aa)) 90W–7Ni–3Fe 90W–7Ni–3Fe and and (b ()b 85W–7Ni–3Fe) 85W–7Ni–3Fe with with 5 wt%5 wt% of tantalum,of tantalum showing, showing grain grain refinement refinement and andthe presencethe presence of porosity of porosity [52]. Reproduced[52]. Reproduced with permission with permission from Bose from and Bose German, and German, Metallurgical Metallurgical Transactions Transactions A; published A; publishedby Springer, by 1988. Springer, 1988.

Table 2. Mechanical properties3. Effect of the Molybdenum rhenium and ontantalum W–Ni–Fe added to the tungsten heavy alloy of W–Ni–Fe. Molybdenum is added toTensile the tungsten Strength heavy alloy of W–Ni–Fe to reduce the dis- Alloy Sintering Process Hardness (HRA) Elongation (%) Reference solution of tungsten in the matrix phase(MPa) and thereby refine the grains, leading to good Sintering atmechanical 1500 °C properties. The grain growth reduction is required in order to get a high- W–8Ni–2Fe–6Re — 1180 13 [49] for 60strength min alloy. W–4.9Ni–2.1Fe Ball milled for 50 h — 997 26.4 W–4.9Ni–2.1Fe–0.2Re Sintered at3.1. 1490 Sintering °C Mechanism— of W–Ni–Fe-Mo1050 Alloy 26 [50] W–4.9Ni–2.1Fe–0.4Re for 90 min As the sintering— progresses, the liquid1090 phase forms early25 in the heavy tungsten alloy Sintering atwith 1480 added °C molybdenum in comparison with the base W–Ni–Fe heavy alloy. This is due to W–7Ni–3Fe–1Re for 120 minthe followed fact that molybdenum— combines with890 nickel to form a eutectic14 liquid at around 1320 ◦C. by heat treatmentHowever, tungsten takes a longer time to form the liquid phase with nickel, which happens W–Re milled for 5 ◦h at 1455 C[55,56]. Hence, the dissolution of tungsten in the matrix phase is restricted[51] in the followed by 48 h of W–7Ni–3Fe–1Re milling of the whole — 952 23 mixture. Sintering at 1480 °C

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early phase of sintering. However, molybdenum starts to dissolve in the matrix due to the early formation of the liquid phase. So, at the early stage of sintering, the microstructure is a combination of tungsten grains and a matrix of Ni–Fe–Mo with a little dissolution of tungsten in the matrix [57]. Therefore, the grain growth in the initial stage of sintering of the WHA with added molybdenum is less than the corresponding growth in pure WHA. During the further progression of the liquid-phase sintering process, the molybdenum gets partitioned between the matrix of Ni–Fe–W and the tungsten-rich grains. It has been reported that the total solubility of W + Mo is constant at a given temperature [57]. The molybdenum and tungsten possess complete solubility in all compositions and at any temperature. The grain growth mechanism at the sintering hold is referred to as the solution and re-precipitation process, where large tungsten grains grow and small grains get dissolved and re-precipitated over the grain boundaries. The precipitation composition at this stage is the combination of W–Mo in the alloy. Initially, the concentration of molybdenum is higher in the precipitation. This leads to a decrease in the molybdenum content in the liquid phase. Now, the tungsten dissolution in the liquid phase increases since the total concentration of tungsten and molybdenum is relatively constant in the liquid [58]. At a certain point, the liquid composition reaches a constant stage and further sintering does not contribute much to the densification of the alloy.

3.2. Microstructural Analysis of W–Ni–Fe-Mo In the WHA with added molybdenum, the controlling factors are the isothermal hold during sintering and the cooling rate. A slow cooling rate and a high sintering temperature hold to the formation of different phases and intermetallic compounds [57,59]. Kemp and German [57] studied these effects on 82W–8Mo–8Ni–2Fe alloy prepared using the injection molding method and sintered at 1500 ◦C for holding times of 30, 120, 480, 960, and 1920 min followed by slow cooling. Smooth, rounded grain structures were obtained for the alloy sintered for 960 min. However, the alloy sintered for 480 min showed a similar microstructure when it was water-quenched instead of slow-cooled as shown in Figure4. Materials 2021, 14, x FOR PEER REVIEWThe slowly cooled alloy exhibited many phase reactions, which were found to exist7 even of 22

after the standard post heat treatment process (1100 ◦C for 60 min). Hence, proper control of the cooling rate is required to obtain an alloy with good mechanical properties.

◦ Figure 4.4. MicrostructureMicrostructure ofof 82W–8Mo–8Ni–2Fe 82W–8Mo–8Ni–2Fe sintered sintered at at 1500 1500C o forC for 480 480 min: min (a:) slowly(a) slowly cooled; cooled (b); water-quenched(b) water-quenched [57]. Reproduced[57]. Reproduced with permissionwith permission from Kempfrom Kemp and German, and German, Journal Journal of the of Less the Common Less Common Metals; Metals; published published by Elsevier, by Elsevier, 1991. 1991. The effect of different proportions of molybdenum addition on the tungsten grain growthThe was effect investigated of different by Hsuproportions and Lin [of60 ].molybdenum The sintering addition profile followed on the tungsten for these alloysgrain growthof W–6.5Ni–2.8Fe, was investigated W–1.9Mo–6.7Ni–2.9Fe, by Hsu and Lin W–8Mo–7Ni–3Fe,[60]. The sintering and profile W–22.4Mo–7.8Ni–3.4Fe followed for these ◦ ◦ alhadloys an ofintermittent W–6.5Ni– isothermal2.8Fe, W– hold1.9Mo at– different6.7Ni–2.9Fe, temperatures. W–8Mo–7Ni At 350–3Fe,C and 500 W–22.4MoC, there– ◦ 7.8Niwas an–3.4Fe isothermal had an hold intermittent of 60 min isothermal and at 1000 holdC againat different the hold temperatures. was for 60 min. At 350 Finally, °C and at ◦ 5001500 °CC,, there the sample was an was isothermal held for hold 5, 15, of 30, 60 60, min 120, and 180, at or 1000 240 omin. C again The the thermal hold profilewas for was 60 min. Finally, at 1500 °C, the sample was held for 5, 15, 30, 60, 120, 180, or 240 min. The thermal profile was attributed to dewaxing, reducing oxides, and, finally, densifying the alloy. The first liquid phase for the alloys occurred at a different range of temperatures. As observed previously, in alloys with added molybdenum the first liquid formation occurs earlier compared with the classical heavy alloy. The different kinds of micro- structures obtained for the sintered alloys infer different kinds of phase partitioning mechanisms occurring in the alloys. The structure not only depends on the amount of molybdenum in the alloy but also on the duration of the sintering hold. Figure 5 shows the effect of sintering holding time on the grain size. The alloys with 8 Mo and 22.4 Mo showed a smaller grain size up to an isothermal hold of 30 min. After this, the grain growth increases at a faster rate, attributed to the instability in the structure causing smaller grains to disappear. It was observed that excess Mo concentration does not con- tribute to the grain refinement at extended isothermal holds. Further, it also leads to the precipitation of intermetallic phases during cooling [61]. A novel way of producing the W–Ni–Fe-Mo alloy was attempted by Lin et al. [62] using separate thin Mo layers over the W–Ni–Fe alloy surface, which diffuses into the alloy during sintering. The Mo atoms diffused into the tungsten grains and binder phase, but the concentration of Mo varied along different sections of the alloy.

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attributed to dewaxing, reducing oxides, and, finally, densifying the alloy. The first liquid phase for the alloys occurred at a different range of temperatures. As observed previously, in alloys with added molybdenum the first liquid formation occurs earlier compared with the classical heavy alloy. The different kinds of microstructures obtained for the sintered alloys infer different kinds of phase partitioning mechanisms occurring in the alloys. The structure not only depends on the amount of molybdenum in the alloy but also on the duration of the sintering hold. Figure5 shows the effect of sintering holding time on the grain size. The alloys with 8 Mo and 22.4 Mo showed a smaller grain size up to an isothermal hold of 30 min. After this, the grain growth increases at a faster rate, attributed to the instability in the structure causing smaller grains to disappear. It was observed that excess Mo concentration does not contribute to the grain refinement at extended isothermal holds. Further, it also leads to the precipitation of intermetallic phases during cooling [61]. A novel way of producing the W–Ni–Fe-Mo alloy was attempted by Lin et al. [62] using separate thin Mo layers over the W–Ni–Fe alloy surface, which diffuses into the alloy Materials 2021, 14, x FOR PEER REVIEW 8 of 22 during sintering. The Mo atoms diffused into the tungsten grains and binder phase, but the concentration of Mo varied along different sections of the alloy.

FigureFigure 5.5.Variation Variation in in mean mean grain grain size size with with sintering sintering holding holding time time [60 [60]]. Reproduced. Reproduced with with permission permis- fromsion Hsufrom et Hsu al., et Journal al., Journal of Materials of Materials Science; Science; published published by Springer, by Springer, 2003. 2003.

3.3.3.3. MechanicalMechanical PropertiesProperties ofof W–Ni–Fe-MoW–Ni–Fe-Mo TheThe additionaddition ofof molybdenummolybdenum toto thethe tungstentungsten heavyheavy alloyalloy increasesincreases thethe strengthstrength ofof thethe alloy.alloy. TableTable3 3shows shows the the hardness, hardness, tensile tensile strength, strength and, and percentage percentage elongation elongation of of the the alloysalloys underunder specific specific processing processing conditions. conditions. With With an an increase increase in thein the molybdenum molybdenum content, con- thetent, hardness the hardness of the of alloys the alloys was found was found to have to anhave inverse an inverse correlation correlation with ductility. with ductility Bose . andBose German and German [63] considered[63] considered the composition the composition of the of alloysthe alloys with with 7/3 7/3 and and 8/2 8/2 ratios ratios of of Ni/Fe.Ni/Fe. ItIt waswas observed observed that that the the hardness hardness and and tensile ten strengthsile strength significantly significantly increased increas whened comparedwhen compared with the with conventional the conventional heavy alloy heavy of W–Ni–Fe alloy of W without–Ni–Fe molybdenum. without molybdenum. However, theHowever, increase the in molybdenumincrease in molybdenum concentration concentration decreased the decrease ductilityd of the the ductility matrix phase. of the Thema- scrutinytrix phase. of theThe results scrutiny shows of the that results the decrease shows that in ductilitythe decrease can bein ductility restricted can to somebe restricted extent withto some the use extent of the with 8/2 the ratio use of Ni/Fe, of the probably8/2 ratio dueof Ni/Fe, to the probably fact that it due slightly to the improves fact that the it tungstenslightly improves solubility the in thetungsten matrix solubility [52]. in the matrix [52]. Sintering of the alloys at lower temperatures was attempted using the spark plasma sintering process [64,65]. The heating rate of the spark plasma sintering process is very high, usually at a rate of 100 °C/min. The alloy W–2Mo–7Ni–3Fe was sintered in SPS in a temperature range of 1000–1250 °C [66] and the microstructure and mechanical proper- ties were investigated. The process provided a refined W-grain size with a maximum of 5 microns. The highest bending strength obtained was 390 MPa. However, the fracture modes showed more pores and intergranular fracture of W-grains, which implies lower ductility of the binder phase. Another investigation using SPS of the alloy with a 7:3 Ni/Fe ratio and varying the Mo content from 0 to 16 wt% and sintering at 1100 °C also yielded good tensile strength and hardness for the alloys [65]. The spark plasma sintering of the alloy with the Ni/Fe ratio maintained at 8:2 was analyzed by Prasad et al. [66]. The molybdenum addition was varied from 0 to 24 wt% and sintered at 1000 °C. The mixed powders were subjected to high-energy ball milling for 40 h under an argon atmosphere before sintering. The density was found to increase with the increase in molybdenum content and was highest for 24 wt% of molybdenum. A similar trend was observed for the tensile strength and hardness. However, the percentage elongation reduced from 28 to 2%.

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Table 3. Mechanical properties of tungsten heavy alloy of W–Ni–Fe with added molybdenum.

Tensile Strength Elongation Alloy Sintering Process Hardness (HRA) Reference (MPa) (%) W–7Ni–3Fe 62.8 923 30 W–8Ni–2FeConventional sintering 1500 ◦C for 63.8 918 36 W–4Mo–8Ni–2Fe30 min 63.8 947 31 [63] W–8Mo–8Ni–2FeHeat treated at 1100 ◦C for 1 h and 65.9 1048 24 W–12Mo–8Ni–2Fewater-quenched 67.4 1119 14 W–16Mo–8Ni–2Fe 68.4 1150 10 W–2Mo–7Ni–3Fe Conventional sintering 1500 ◦C for 63 948 28 W–4Mo–7Ni–3Fe30 min 64 980 24 [57] W–8Mo–7Ni–3FeHeat treated at 1100 ◦C for 1 h and 68 1030 20 W–12Mo–7Ni–3Fewater-quenched 68 1100 10 SPS 390 bending W–2Mo–7Ni–3Fe 1000–1250 ◦C For 8 min at 50 MPa 63.9 at 1250 ◦C —[64] strength at 1150 ◦C 100 ◦C/min W–7Ni–3Fe–4Mo 286 HV 993 24 SPS W–7Ni–3Fe–8Mo 336 HV 1050 20 1100 ◦C For 8 min at 50 MPa [65] W–7Ni–3Fe–12Mo 354 HV 1120 10 100 ◦C/min W–7Ni–3Fe–16Mo 372 HV 1150 7 W–8Ni–2Fe–0Mo 63 975 28 W–8Ni–2Fe–6MoHigh-energy ball milling for 40 h and 65 1025 22 W–8Ni–2Fe–12MoSPS-sintered at 1000 ◦C for 8 min at 68 1120 14 [66] W–8Ni–2Fe–18Mo30 MPa and 100 ◦C/min 72 1160 05 W–8Ni–2Fe–24Mo 75 1250 02

Sintering of the alloys at lower temperatures was attempted using the spark plasma sintering process [64,65]. The heating rate of the spark plasma sintering process is very high, usually at a rate of 100 ◦C/min. The alloy W–2Mo–7Ni–3Fe was sintered in SPS in a temperature range of 1000–1250 ◦C[66] and the microstructure and mechanical properties were investigated. The process provided a refined W-grain size with a maximum of 5 microns. The highest bending strength obtained was 390 MPa. However, the fracture modes showed more pores and intergranular fracture of W-grains, which implies lower ductility of the binder phase. Another investigation using SPS of the alloy with a 7:3 Ni/Fe ratio and varying the Mo content from 0 to 16 wt% and sintering at 1100 ◦C also yielded good tensile strength and hardness for the alloys [65]. The spark plasma sintering of the alloy with the Ni/Fe ratio maintained at 8:2 was analyzed by Prasad et al. [66]. The molybdenum addition was varied from 0 to 24 wt% and sintered at 1000 ◦C. The mixed powders were subjected to high-energy ball milling for 40 h under an argon atmosphere before sintering. The density was found to increase with the increase in molybdenum content and was highest for 24 wt% of molybdenum. A similar trend was observed for the tensile strength and hardness. However, the percentage elongation reduced from 28 to 2%.

4. Effect of Oxide Dispersions on WHA The tensile and impact properties of the tungsten heavy alloy also depend on the segregation of impurities like H, P, S, C, and O over the W and matrix interface [67,68]. This causes embrittlement in the alloy, leading to reduced mechanical properties. Based on the percentage of segregation of impurities, the bonding strength between the tungsten and the matrix is altered and the continuity of the matrix is affected, leading to fracture. Some elements like H can be removed by heat treatment. The dispersion technique is used to lower the effect of embrittlement by the formation of stable compounds, which depend on the type of dispersion used.

4.1. Effect of Lanthanum and on W–Ni–Fe The strength and recrystallization temperature of tungsten materials can be improved by dispersing oxides of lanthanum or yttria [54]. The addition of lanthanum to Materials 2021, 14, 1660 9 of 20

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successfully reduced the temper embrittlement that occurs due to P and S [69,70]. This Microstructureis the impetus forAnalysis experimenting and Mechanical with oxides Properties of lanthanum with tungsten heavy alloys. Microstructure Analysis and Mechanical Properties Wu et al. [71] investigated the microstructure and mechanical properties of 78W– MicrostructureWu et al. [71 Analysis] investigated and Mechanical the microstructure Properties and mechanical properties of 78W– 2.5Ni–2.0Fe alloy with the addition of approximately 17 wt% of molybdenum, varying 2.5NiWu–2.0Fe et al.alloy [71 with] investigated the additi theon of microstructure approximately and 17 mechanicalwt% of molybdenum properties, ofvarying 78W– proportions of lanthanum (0.2–0.8 wt%), and 0.2 wt% of Mn. The powder mixture was propo2.5Ni–2.0Fertions of alloy lanthanum with the ( addition0.2–0.8 wt% of approximately), and 0.2 wt% 17of wt%Mn. The of molybdenum, powder mixture varying was cold iso-statically pressed and sintered under a hydrogen atmosphere at 1510 °C for 90 coldproportions iso-statically of lanthanum pressed (0.2–0.8and sintered wt%), under and 0.2 a wt%hydrogen of Mn. atmosphere The powder at mixture 1510 ° wasC for cold 90 min. The microstructure of the alloys with added La is typical to that of a classical◦ tung- miniso-statically. The microstructure pressed and of sintered the alloys under with aadded hydrogen La is atmosphere typical to that at 1510of a classicalC for 90 tung- min. sten heavy alloy as shown in Figure 6. In addition to the W and the matrix phase, there stenThe heavy microstructure alloy as shown of the alloysin Figure with 6. addedIn addition La is to typical the W to and that the of matrix a classical phase, tungsten there exists a secondary phase with La as the major component. From the X-Ray Diffraction existsheavy a alloy secondary as shown phase in Figurewith La6. Inas addition the major to component. the W and the From matrix the phase,X-Ray thereDiffracti existson (XRD) pattern, the phases were identified as LaMnO3 and Mn3O4. The phases were stable (aXRD secondary) pattern phase, the phases with La were as theidentified major component.as LaMnO3 and From Mn the3O4 X-Ray. The phases Diffraction were (XRD)stable in . This reduces the segregation of the oxygen element on the W-matrix interface inpattern, nature. the This phases reduces were the identified segregation as LaMnOof the oxygen3 and Mnelement3O4. Theon the phases W-matrix were interface stable in and enhances its bonding. The tensile strength increases from 291 MPa for the alloy andnature. enhances This reduces its bonding. the segregation The tensile of the strength oxygen increases element on from the 291 W-matrix MPa for interface the alloy and without La addition to 903 MPa for the alloy with 0.4 wt% La. The elongation also in- withoutenhances La its addition bonding. to The903 tensileMPa for strength the alloy increases with 0.4 from wt% 291 La. MPa The for elongation the alloy withoutalso in- creases to 4.7%. The fracture surface analysis also supports the data. The fractography of creasesLa addition to 4.7%. to 903The MPa fracture for thesurface alloy analysis with 0.4 also wt% supports La. The the elongation data. The alsofractography increases of to the 0.4% La alloy revealed a ductile fracture with a rupture in the matrix phase as shown the4.7%. 0.4% The La fracture alloy revealed surface analysisa ductile also fracture supports with the a rupture data. The in fractographythe matrix phase of the as 0.4%shown La in Figure 7. However, for the alloys with a higher percentage of La (0.6 and 0.8 wt%), the inalloy Figure revealed 7. However, a ductile for fracture the alloys with with a rupture a higher in percentage the matrix of phase La (0.6 as shownand 0.8 in wt%)Figure, the7 . tensile strength and elongation were observed to decrease. This change in trend was at- tensileHowever, strength for the and alloys elongation with awere higher observed percentage to decrease of La. (0.6 This and change 0.8 wt%), in trend the wa tensiles at- tributed to the formation of more La-rich phases, which leads to the discontinuity in the tributedstrength to and the elongation formation were of more observed La-rich to decrease.phases, which This changeleads to in the trend discontinuity was attributed in the to matrix. matrix.the formation of more La-rich phases, which leads to the discontinuity in the matrix.

Figure 6. Microstructure of the W W–Ni–Fe-Mo–Ni–Fe-Mo alloy (a) without La and (b) with 0.4% La [[71]71].. Reproduced with permission Figurefrom Wu 6. Microstructureet al., International of the Journal W–Ni of–Fe Refractory-Mo alloy Metals(a) without and HardLa and Materials; (b) with 0.4%published La [71] by. Reproduced Elsevier, 1999 with. permission fromfrom Wu Wu et al., International Journal of Refractory Metals and Hard Materials;Materials; publishedpublished byby Elsevier,Elsevier, 1999.1999.

Figure 7. Fracture surfacessurfaces ofof thetheW–Ni–Fe-Mo W–Ni–Fe-Mo alloy alloy (a ()a without) without La La and and (b ()b with) with 0.4% 0.4% La La [71 [71]]. Reproduced. Reproduced with with permission permis- Figuresionfrom from Wu 7. Fracture etWu al., et International al., surfaces International of Journal the WJournal– ofNi Refractory–Fe of- MoRefractory alloy Metals (a )Metals without and Hardand La Hard Materials;and (Materials;b) with published 0.4% published La by [71] Elsevier, .by Reproduced Elsevier, 1999. 1999 with. permis- sion from Wu et al., International Journal of Refractory Metals and Hard Materials; published by Elsevier, 1999. TheThe effect effect of La o onn reducing the embrittlement caused by the phosphorous element The effect of La on reducing the embrittlement caused by the phosphorous element wawass investigated by Hong et al al.. [[6767]. A higher concentration of phosphorous leads to a washarps investigated decrease in by the Hong impact et strengthal. [67]. ofA thehigher alloy concentration as evident from of phosphorous Figure8. This isleads evident to a sharp decrease in the impact strength of the alloy as evident from Figure 8. This is evi- sharpwiththe decrease amount in of the phosphorous impact strength present of inthe the alloy fractured as evident surfaces from of Figure the alloy 8. subjectedThis is evi- to dent with the amount of phosphorous present in the fractured surfaces of the alloy sub- dent with the amount of phosphorous present in the fractured surfaces of the alloy sub- jected to an impact test. In the work by Hong et al., lanthanum was added to the 93W– jected to an impact test. In the work by Hong et al., lanthanum was added to the 93W–

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an impact test. In the work by Hong et al., lanthanum was added to the 93W–4.9Ni–2.1Fe 4.9Ni–2.1Fe alloy to study its influence on limiting the embrittlement effect of phospho- alloy4.9Ni to–2.1Fe study alloy its influenceto study its on influence limiting theon embrittlementlimiting the embrittlement effect of phosphorous. effect of phospho- The W rous. The W powder contained 19 ppm of phosphorous. For a better analysis, the alloy powderrous. The contained W powder 19 ppmcontained of phosphorous. 19 ppm of Forphosphorous. a better analysis, For a thebetter alloy analysis, was also the doped alloy was also doped with 150 ppm of P and lanthanum was added at the percentage of 0.03, withwas also 150 ppmdoped of with P and 150 lanthanum ppm of P was and added lanthanum at the was percentage added at of the 0.03, percentage 0.1, and 0.3. of 0.03, The 0.1, and 0.3. The La addition did not reveal any significant improvement in the ultimate La0.1, addition and 0.3. didThe notLa revealaddition any did significant not reveal improvement any significant in improveme the ultimatent tensile in the strengthultimate tensile strength and hardness of the alloy in comparison with the undoped specimen. andtensile hardness strength of the and alloy hardness in comparison of the alloy with in the comparison undoped specimen.with the undoped There was specimen. a slight There was a slight reduction in the elongation from 20 to 17%. However, the impact en- reductionThere was in a theslight elongation reduction from in the 20 toelongation 17%. However, from 20 the to impact 17%. However energy of, the the impact alloy with en- ergy of the alloy with La addition showed a substantial increase with the increase in the Laergy addition of the alloy showed with a substantialLa addition increase showed witha substantial the increase increase in the wit percentageh the increase of La. in The the percentage of La. The variation in impact energy with respect to La addition is shown in variationpercentage in of impact La. The energy variation with in respect impact to energy La addition with respect is shown to La in addition Figure9. is The shown La in in Figure 9. The La in association with O and P is expected to form a stable compound in the associationFigure 9. The with La in O associa and P istion expected with O toand form P is aexpected stable compound to form a stable in the compound form of LaPO in the4. Additionally,form of LaPO it4. is A stateddditionally, to form it anotheris statedstable to form compound another of stable La2O compound3 [72,73]. Thus, of La the2O3 form of LaPO4. Additionally, it is stated to form another stable compound of La2O3 La[72 addition,73]. Thus was, the found La addition to reduce was the found segregation to reduce of the phosphorous segregation at of the phosphorous interfaces for at thethe [72,73]. Thus, the La addition was found to reduce the segregation of phosphorous at the alloysinterfaces with for a relativelythe alloys higher with a concentration relatively higher of P concentration and under slow of coolingP and under conditions slow cool- after interfaces for the alloys with a relatively higher concentration of P and under slow cool- heating conditions treatment. after heat treatment. ing conditions after heat treatment.

Figure 8. Effect of P on the impact energy of 93W-4.9Ni-2.1Fe [67]. Reproduced with permission FigureFigure 8.8. Effect of P P on on the the impa impactct energy energy of of 93W 93W-4.9Ni-2.1Fe-4.9Ni-2.1Fe [67 [67]. ].Reproduced Reproduced with with permission permission from Hong et al., Metallurgical Transactions A; published by Springer, 1991. fromfrom HongHong etet al.,al., MetallurgicalMetallurgical TransactionsTransactions A; A; published published by by Springer, Springer, 1991. 1991.

Figure 9. Effect of La on the impact energy of the alloy doped with 150 ppm of P [67]. Reproduced Figure 9. Effect of La on the impact energy of the alloy doped with 150 ppm of P [67]. Reproduced Figurewith permission 9. Effect of from La on Hong the impactet al., Metallurgical energy of the Transactions alloy doped A; with published 150 ppm by of Springer, P [67]. Reproduced 1991. withwith permissionpermission fromfrom HongHong etet al.,al., MetallurgicalMetallurgical TransactionsTransactions A; A; published published by by Springer, Springer, 1991. 1991. The addition of lanthanum oxide to the tungsten material was found to improve the The addition of lanthanum oxide to the tungsten material was found to improve the fracture strength at room temperature after high-temperature annealing. The recrystal- fracture strength at room temperature after high-temperature annealing. The recrystal-

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The addition of lanthanum oxide to the tungsten material was found to improve the fracture strength at room temperature after high-temperature annealing. The recrystalliza- lizationtion temperature temperature was was also also improved improved [74 [74]. The]. The tungsten tungsten alloy alloy with with La La2O2O33 addedadded gave a betterbetter performanceperformance than than the the undoped undoped specimen. specimen. The behavior The behavior of the lanthanum-oxide-of the lantha- numdispersed-oxide tungsten-dispersed heavy tungsten alloy heavy under alloy high under heating high rate heating conditions rate was conditions investigated was in- by veAyyapparajstigated by et A al.yyapparaj [75]. To et avoid al. [75 extended]. To avoid exposure extended of theexposure alloy toof a the high alloy temperature to a high temperatureduring sintering during and sintering to reduce and the to implications, reduce the implications, spark plasma spark sintering plasma was sintering used, which was used,is a high-rate which is sintering a high-rate process. sintering The process. tungsten The alloy tungsten considered alloy in considered the experiment in the was ex- perimentW-7Ni-3Fe. was The W amount-7Ni-3Fe. of The La2 O amount3 addition of La was2O3 varied addition from was 0.25 varied to 1.00 from wt%. 0.25 The to sinter- 1.00 ◦ ◦ wt%.ing parameters The sintering included parameters a temperature included ofa temperature 1100 C, a heating of 1100 rate °C, of a 100heatingC/min, rate of and 100 a °pressureC/min, and of 30 a MPa.pressure The of density 30 MPa. of The the oxide-disperseddensity of the oxide heavy-dispersed alloy was heavy more alloy than was that moreof the than undoped that of heavy the undoped alloy. The heavy La2 alloy.O3 particles The La2 gotO3 particles distributed got uniformlydistributed over uniformly the W overgrains the and W thegrains matrix and phase,the matrix which phase contributed, which contributed to the matrix to strengtheningthe matrix strengthening effect. The effect.elemental The distribution elemental di isstribution shown in Figureis shown 10. in Thus, Figure the tensile10. Thus strength, the tensile and hardness strength of and the hardnessalloy increased of the withalloy theincreased increase with in thethe concentration increase in the of concentration the lanthanum ofoxide, the lanthanum resulting oxidein an, alloyresulting with in good an alloy strength with good relative strength to the relative undoped to the one. undoped A high one. tensile A high strength tensile of 1110 MPa was obtained for the alloy with 1 wt% La O added. The tungsten grain size strength of 1110 MPa was obtained for the alloy with2 13 wt% La2O3 added. The tungsten grainalso got size refined also got to refined 7.89 microns. to 7.89 microns. This was This due was to the due effect to the of effect the oxide of the dispersion oxide disper- and the high-temperature sintering process. However, the percentage elongation of the alloy sion and the high-temperature sintering process. However, the percentage elongation of decreased with the increase in the oxide dispersion of the lanthanum due to the brittleness the alloy decreased with the increase in the oxide dispersion of the lanthanum due to the induced in the alloy [76,77]. The mechanical properties of the heavy alloy with lanthanum brittleness induced in the alloy [76,77]. The mechanical properties of the heavy alloy with addition are presented in Table4. lanthanum addition are presented in Table 4.

Figure 10. Elemental distribution of SEM micrograph on (a) spark-plasma-sintered W-7Ni-3Fe-0.5La2O3; (b) Ni; (c) W; (d) Figure 10. Elemental distribution of SEM micrograph on (a) spark-plasma-sintered W-7Ni-3Fe-0.5La2O3;(b) Ni; (c) W; Fe; (e) La; and (f) O [75]. Reproduced with permission from Muthuchamy et al., Rare Metals; published by Springer, 2020 (d) Fe; (e) La; and (f)O[75]. Reproduced with permission from Muthuchamy et al., Rare Metals; published by Springer, 2020

Table 4. Mechanical properties of W–Ni–Fe with lanthanum oxide. 4.2. Effect of Yttrium and Yttrium Oxide on W–Ni–Fe Tensile Strength Alloy Sintering ProcessYttrium Hardness is another (HRC) rare earth element used in theElongation production % of tungstenReference heavy alloys to improve its properties. Early investigations(MPa) of yttrium-oxide-dispersed tungsten material W–17.1Mo– Conventionalshowed sinter- good resistance over the grain boundaries against molten metals [78,79]. 2.5Ni-2Fe–0.2La– ing at 1510 °C for 90 34 650 2.2 [67] The grains got refined with the addition of Y2O3 in comparison with pure tungsten. The min under a hydro- 0.2Mn effect of sintering temperature on the addition of 5, 10, and 20 vol% of yttrium oxide to gen atmosphere tungsten was studied. The relative density increased with the increase in the volume of the Conventional sinter- oxide particles. The Y O particles grew larger in size with the increase in the temperature W–16.9Mo–2.5Ni– ing at 1510 °C for 90 2 3 from 1800 to 2200 ◦30C. However, the bending903 strength decreased4.7 with increasing[67] sintering 2Fe–0.4La–0.2Mn min under a hydro- gen atmosphere 90W–7Ni–3Fe Spark plasma sinter- 138 475 0.64 [75]

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temperature. The Y2O3 oxide dispersion on the tungsten heavy alloy showed a similar behavior of refining the tungsten grain size with an increase in the content of the oxide at a given sintering temperature and time [80]. The heavy alloy of 93W–5.6Ni–1.4Fe was alloyed with 0.1, 0.5, 1, and 5 wt% of Y2O3 powder particles in a ball mill for 72 h. After compaction at 100 MPa, the green compacts were sintered at a temperature of 1485 ◦C for 60 min in a hydrogen atmosphere. The oxide particles got widely distributed on the tungsten–matrix interfaces, thereby restricting the dissolution of tungsten in the matrix phase and resulting in refinement of the tungsten grains [81]. Figure 11 shows the distribution of the Y2O3 particles in the alloy. The tungsten grain size reduced drastically from 27 microns to 10 microns with the increase in the amount of oxide in the heavy alloy. This positive trend is represented in Figure 12. To understand the mechanical behavior of the alloys, they were subjected to a tensile test and a high-temperature compression test. There was a slight decrease in the tensile strength and elongation for the alloy with 0.1 wt% Y2O3 added (828 MPa and 14.6%, respectively) compared with the undoped alloy (940 MPa and 30%, respectively). This was attributed to the difference in the relative of the alloys. However, relatively better strength and elongation were obtained for the doped alloy when it was sintered for 120 min with an increase in density.

Table 4. Mechanical properties of W–Ni–Fe with lanthanum oxide.

Hardness Tensile Strength Elongation Alloy Sintering Process Reference (HRC) (MPa) % W–17.1Mo–2.5Ni-2Fe– Conventional sintering at 1510 ◦C for 34 650 2.2 [67] 0.2La–0.2Mn 90 min under a hydrogen atmosphere W–16.9Mo–2.5Ni–2Fe– Conventional sintering at 1510 ◦C for 30 903 4.7 [67] 0.4La–0.2Mn 90 min under a hydrogen atmosphere Spark plasma sintering at 1100 ◦C for 90W–7Ni–3Fe 5 min in a vacuum with a heating rate 138 475 0.64 [75] of 100 ◦C/min Spark plasma sintering at 1100 ◦C for W–7Ni–3Fe-0.50La2O3 5 min in a vacuum with a heating rate 370 822 0.95 [75] of 100 ◦C/min Spark plasma sintering at 1100 ◦C for W–7Ni–3Fe-1.00La2O3 5 min in a vacuum with a heating rate 533 1110 0.64 [75] Materials 2021, 14, x FOR PEER REVIEW of 100 ◦C/min 14 of 22

Figure 11. SEM micrograph of a mechanically alloyed oxide dispersion of 1 wt% Y2O3 in Figure 11. SEM micrograph of a mechanically alloyed oxide dispersion of 1 wt% Y2O3 in W-5.6Ni- W-5.6Ni-1.4Fe sintered at◦ 1485 °C for 60 min [80]. Reproduced with permission from Ryu et al., 1.4FeMaterials sintered Science at and 1485 Engineering:C for 60 minA; published [80]. Reproduced by Elsevier, with2003. permission from Ryu et al., Materials Science and Engineering: A; published by Elsevier, 2003.

Figure 12. Variation in grain size in mechanically alloyed and sintered W-5.6Ni-1.4Fe with in- creasing Y2O3 content [80]. Reproduced with permission from Ryu et al., Materials Science and Engineering: A; published by Elsevier, 2003.

The compression test was carried out at 800o C to study the deformation behavior of the alloy at elevated temperatures. The test showed a satisfactory result with an im- provement in the compression strength as the oxide content was increased. The alloy was able to maintain the oxide dispersion strengthening effect even at high temperatures. Another investigation by Fan et al. [82] with an yttrium-oxide-dispersed tungsten heavy alloy showed good tensile strength as well as good ductility with the addition of a low percentage of the oxide. Fine-grained alloys were prepared using a mechanical alloying process by dispersing 0.02–0.08 wt% of Y2O3 into 90W–7Ni–3Fe in a ball mill for 40 h at 200 rpm, which resulted in composite powder with a size of 21.4 nm. The sintering was done at 1480 °C for 30 min under a hydrogen atmosphere. All the oxide-dispersed sam-

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Materials 2021, 14, 1660 Figure 11. SEM micrograph of a mechanically alloyed oxide dispersion of 1 wt% Y2O3 in 13 of 20 W-5.6Ni-1.4Fe sintered at 1485 °C for 60 min [80]. Reproduced with permission from Ryu et al., Materials Science and Engineering: A; published by Elsevier, 2003.

Figure 12. Variation in graingrain sizesize inin mechanicallymechanically alloyed alloyed and and sintered sintered W-5.6Ni-1.4Fe W-5.6Ni-1.4Fe with with increasing in-

creasY2O3ingcontent Y2O3 [content80]. Reproduced [80]. Reproduced with permission with permission from Ryu from et al., Ryu Materials et al., Materials Science andScience Engineering: and Engineering:A; published A; by published Elsevier, 2003. by Elsevier, 2003.

The compression compression test test was was carried carried ou outt at at 800 800o C◦ Cto to study study the the deformation deformation behavior behavior of theof the alloy alloy at at elevated elevated temperature temperatures.s. The The test test showed showed a asatisfactory satisfactory result result with with an an im- im- provement in in the the compression compression strength strength as as the the oxide oxide content content was was increased. increased. The Thealloy alloy was ablewas ableto maintain to maintain the theoxide oxide dispersi dispersionon strengthening strengthening effect effect even even at at high high temperatures. temperatures. AnotheAnotherr investigation by Fan et al.al. [[8282] withwith an yttrium-oxide-dispersedyttrium-oxide-dispersed tungsten heavy alloy showed good tensile strength as well as good ductility with the addition of a low percentage of the oxide. Fine Fine-grained-grained alloys were prepared using a mechanicalmechanical alloyingalloying process by dispersing dispersing 0.02 0.02–0.08–0.08 wt% wt% of of Y Y2O2O3 3intointo 90W 90W–7Ni–3Fe–7Ni–3Fe in ina ball a ball mill mill for for 40 40h at h 200at 200 rpm rpm,, which which resulted resulted in composite in composite powder powder with with a size a sizeof 21.4 of21.4 nm. nm.The Thesintering sintering was ◦ donewas done at 1480 at 1480°C forC 30 for m 30in under min under a hydrogen a hydrogen atmosphere. atmosphere. All the All oxide the oxide-dispersed-dispersed sam- samples showed a relative density of more than 99%. Generally, nano powder particles are prone to bubble formation during liquid phase sintering, which will lead to a lower density for the alloys. However, small amount of oxide dispersion inhibits the bubble production and enhances the density. The alloy with 0.04 wt% Y2O3 remarkably gave a high tensile strength of 1050 MPa as well as a good ductility of 30%. Generally, tensile strength and ductility have an inverse correlation. However, the effective performance of this alloy may be due to its fine-grained structure and the homogeneous distribution of the oxide phase. The oxides absorb the impurities and oxygen and prevent them from segregating over the tungsten–matrix interface. A high temperature tensile test in the range of 25–1100 ◦C on a fine grained 93W–4.9Ni–2.1Fe–0.03Y alloy showed a superior ultimate tensile strength to the test on the coarse-grained alloy of 93W–4.9Ni–2.1Fe [83]. A model alloy of W–Ni–Fe-Mo-Co was chosen by Chen et al. [84] to investigate the mechanical properties of the sintered alloy with and without yttrium oxide dispersion. The dispersed alloy showed a relatively high hardness of 430 HV, giving a 17% increase in hardness compared with the undispersed alloy. The mechanical properties of some oxide-dispersed tungsten heavy alloys are presented in Table5. The tungsten heavy alloys were found to be a replacement for Depleted Uranium (DU) alloys in military applications, especially as armor-piercing penetrators. However, the performance of WHAs is not on par with DU alloys at high strain rates [85,86]. High density and good penetration characteristics are required to obtain an alloy with good performance for armor application. The characteristics include formation of a localized Materials 2021, 14, x FOR PEER REVIEW 15 of 22

ples showed a relative density of more than 99%. Generally, nano powder particles are prone to bubble formation during liquid phase sintering, which will lead to a lower den- sity for the alloys. However, small amount of oxide dispersion inhibits the bubble pro- duction and enhances the density. The alloy with 0.04 wt% Y2O3 remarkably gave a high tensile strength of 1050 MPa as well as a good ductility of 30%. Generally, tensile strength and ductility have an inverse correlation. However, the effective performance of this al- loy may be due to its fine-grained structure and the homogeneous distribution of the oxide phase. The oxides absorb the impurities and oxygen and prevent them from seg- regating over the tungsten–matrix interface. A high temperature tensile test in the range of 25–1100 °C on a fine grained 93W–4.9Ni–2.1Fe–0.03Y alloy showed a superior ultimate tensile strength to the test on the coarse-grained alloy of 93W–4.9Ni–2.1Fe [83]. A model alloy of W–Ni–Fe-Mo-Co was chosen by Chen et al. [84] to investigate the mechanical properties of the sintered alloy with and without yttrium oxide dispersion. The dispersed alloy showed a relatively high hardness of 430 HV, giving a 17% increase in hardness compared with the undispersed alloy. The mechanical properties of some ox- ide-dispersed tungsten heavy alloys are presented in Table 5. The tungsten heavy alloys were found to be a replacement for Depleted Uranium Materials 2021, 14, 1660 (DU) alloys in military applications, especially as armor-piercing penetrators. However,14 of 20 the performance of WHAs is not on par with DU alloys at high strain rates [85,86]. High density and good penetration characteristics are required to obtain an alloy with good performance for armor application. The characteristics include formation of a localized shearshear band band at at low low strains strains and and a a reduction reduction in in the the thermal thermal softening softening effect. effect. Several Several works works onon enhancing enhancing the the adiabatic adiabatic shear shear failure failure of of coarse-grained coarse-grained tungsten tungsten heavy heavy alloys alloys have have beenbeen carried carried out out over over the the last last decade. decade. Gong Gong et et al. al. [ 87[87]] studied studied the the dynamic dynamic behavior behavior of of a a −1 fine-grainedfine-grained alloy alloy of of 93W–4.9Ni–2.1Fe–0.03Y 93W–4.9Ni–2.1Fe–0.03Y in in the the strain strain range range of of 1200 1200 to to 1900 1900 s s−.1. The The −1 shearshear band band occurred occurred in in the the alloy alloy tested tested at at the the strain strain rate rate of of 1900 1900 s s−1and and is is represented represented in in FigureFigure 13 13.. TheThe grainsgrains elongateelongate inin thethe bandband regionregion due due to to the the intensive intensive localized localized plastic plastic flow.flow.The The adiabatic adiabatic shearshear failurefailurein in the the fine-grained fine-grained alloy alloy seems seems to to occur occur not not due due to to the the thermalthermal softening softening as as in in the the case case of of coarse-grained coarse-grained alloys alloys but but due due to to the the premature premature shear shear localization.localization. The The effect effect may may be be attributed attributed to to fine fine grains grains and and the the increase increase in in the the number number of of graingrain boundaries, boundaries, which which reduces reduces the the rate rate sensitivity sensitivity and and strain strain hardening hardening [ 88[88].].

FigureFigure 13. 13.The The adiabatic adiabatic shear shear band band is is visible visible inin the the specimenspecimendynamically dynamicallytested tested atat aastrain strain raterate ofof 1.9 × 103 s−1 [87]. Reproduced with permission from Gong et al., Materials Science and Engineering: 1.9 × 103 s−1 [87]. Reproduced with permission from Gong et al., Materials Science and Engineering: A; published by Elsevier, 2010. A; published by Elsevier, 2010.

Table 5. Mechanical properties of W–Ni–Fe with yittrium and Y2O3.

Hardness Tensile Compression Elongation Alloy Sintering Process Reference (HRB) Strength (MPa) Strength (MPa) (%) W–5.6Ni–1.4Fe- Sintering at 1485 ◦C for — 828 — 14.6 [80] 00.1Y2O3 60 min Sintering at 1485 ◦C for W–5.6Ni–1.4Fe– 120 min in a hydrogen — 883 — 18.4 [80] 0.1Y O 2 3 atmosphere W–7Ni–3Fe ◦ Sintering at 1480 C for — 923 8 — [82] (Fine grained alloy) 30 min in a hydrogen W–7Ni–3Fe–0.04Y O 2 3 atmosphere — 1050 30.8 — [82] (Fine grained alloy) ◦ W–4.9Ni–2.1Fe ◦ 580 at 600 C Pre-sintering at 900 C — ——[83] (Coarse grained) 330 at 800 ◦C for 120 min and sintering ◦ W–4.9Ni–2.1Fe–0.03Y ◦ 620 at 600 C at 1460 C for 90 min in a — ◦ ——[83] (Fine grained) hydrogen atmosphere 460 at 800 C W–7Ni–3Fe 68 586 — 0.64 Spark plasma sintering W–7Ni–3Fe–0.25YSZ 109 892 — 1.83 [89] at 1100 ◦C with 30 MPa W–7Ni–3Fe–1YSZ 105 658 — 2.24

A novel tungsten heavy alloy was developed by Muthuchamy et al. [89] by dispersing yttria-stabilized zirconia (YSZ) into a W–Ni–Fe alloy with a 7:3 nickel–iron ratio. The alloy was sintered in SPS at 1100 ◦C. The amount of dispersed particles varied from 0 to 1.0 wt%. The sintered density decreased with an increase in YSZ content. The increase in the oxide phase resulted in the reduction of the binder phase, leading to a decrease in Materials 2021, 14, x FOR PEER REVIEW 16 of 22

Table 5. Mechanical properties of W–Ni–Fe with yittrium and Y2O3.

Tensile Strength Compression Alloy Sintering Process Hardness (HRB) Elongation (%) Reference (MPa) Strength (MPa) W–5.6Ni–1.4Fe- Sintering at 1485 — 828 — 14.6 [80] 00.1Y2O3 °C for 60 min Sintering at 1485 W–5.6Ni–1.4Fe– °C for 120 min in a — 883 — 18.4 [80] 0.1Y2O3 hydrogen atmos- phere W–7Ni–3Fe (Fine grained al- — 923 8 — [82] Sintering at 1480 loy) °C for 30 min in a W–7Ni–3Fe– hydrogen atmos- 0.04Y2O3 phere — 1050 30.8 — [82] (Fine grained al- loy) W–4.9Ni–2.1Fe Pre-sintering at 580 at 600 °C — — — [83] (Coarse grained) 900 °C for 120 min 330 at 800 °C and sintering at W–4.9Ni–2.1Fe– 1460 °C for 90 min 620 at 600 °C 0.03Y — — — [83] in a hydrogen 460 at 800 °C (Fine grained) atmosphere W–7Ni–3Fe Spark plasma sin- 68 586 — 0.64 W–7Ni–3Fe– tering at 1100 °C 109 892 — 1.83 [89] 0.25YSZ with 30 MPa W–7Ni–3Fe–1YSZ 105 658 — 2.24

A novel tungsten heavy alloy was developed by Muthuchamy et al. [89] by dis- Materials 2021, 14, 1660 persing yttria-stabilized zirconia (YSZ) into a W–Ni–Fe alloy with a 7:3 nickel–iron15 ratio. of 20 The alloy was sintered in SPS at 1100 °C. The amount of dispersed particles varied from 0 to 1.0 wt%. The sintered density decreased with an increase in YSZ content. The increase in the oxide phase resulted in the reduction of the binder phase, leading to a decrease in density. However, However, the the density density obtained obtained for for the the doped doped alloys alloys was was higher higher than thanthat obtainedthat ob- fortained the for undoped the undoped one. The one. optical The andoptical SEM and micrographs SEM micrographs for the 0.25for the wt% 0.25 doped wt% alloy doped as shownalloy as in shown Figure in14 revealFigure good14 reveal dispersion good of dispersion the oxide of phase. the oxide The tensile phase. strength The tensile and hardnessstrength and were hardness also higher were for also this higher alloy. However, for this alloy. the ductility However, for the all theductility alloys for was all very the low,alloys which was may very have low, beenwhich due may to the have restrictions been due in to the the dislocation restrictions movements in the dislocation along the tungsten–matrixmovements along interface the tungsten due to–matrix the presence interface of due more to aggregates. the presence of more aggregates.

FigureFigure 14.14.The The SEM SEM and and optical optical micrographs micrographs of of SPS-sintered SPS-sintered alloy alloy with with 0.25 0.25 wt% wt% yttria-stabilized yttria-stabilized zirconia zirconia (YSZ) (YSZ [89].) “Re-[89]. produced“Reproduced with with permission permission from Muthuchamy from Muthuchamy et al., Arabian et al., Arabian Journal for Journal Science for and Science Engineering; and Engineering; published bypub Springer”.lished by Springer”. 5. Discussion and Conclusions The rare earth metals, like yttrium, lanthanum, and their oxides, and refractory metals, like molybdenum, tantalum, rhenium, and niobium, are effective in refining the tungsten grain size of the tungsten heavy alloy of W–Ni–Fe by restricting the tungsten dissolution in the liquid phase during sintering of the alloy. Grain size is a significant factor in obtaining a good yield strength of the alloy. With a reduced grain size, the probability of moving the dislocations formed at the boundaries to induce plasticity is lower [90]. This is known as the Hall-Petch strengthening effect, which results in a superior yield strength for the alloy. The yield strength and grain size have an inverse correlation as expressed by Hall and Petch [91]. To get better mechanical properties and homogeneity, the investigators are more interested in the processing of nano-sized compositions of the tungsten heavy alloy. This is obtained through high-energy ball milling of the as-purchased powder particles for several hours. Particle sizes in the range of 4 to 26 nm can be produced through this process. The major issue with this technique is the contamination of the powders with the milling medium of the balls and the atmosphere. This leads to segregation of impurities on the tungsten boundaries and formation of intermetallic precipitates during the sintering process. Some of the techniques, like using alloy-coated milling media with a protective atmosphere and using surfactants, can reduce the contamination effect [92,93]. The major requirement is to obtain an alloy with good strength without a significant drop in ductility. The addition of the rhenium element positively satisfies this requirement as can be seen from the investigated data presented in Table2. However, the high cost of the rhenium element limits its usage as an effective additive for tungsten heavy alloys. Now, since the element cost is reduced due to the increase in rhenium recycling and the drop in demand for the element in catalysts, more investigations using rhenium can be expected in the near future. The factor to be controlled in the processing of rhenium–tungsten heavy alloys is the presence of undissolved rhenium particles over the tungsten phase. The Re-rich regions may become crack initiation spots, leading to a reduction in the alloy’s strength. Tantalum is not used commercially with tungsten alloys because of the brittleness of the structure in a wide temperature range and the formation of residual pores during the sintering process. Although it provides a high tensile strength [54] for the alloy, the ductility of the matrix in terms of percentage elongation is reduced to a very low value. Materials 2021, 14, 1660 16 of 20

Molybdenum is another promising refractory element that provides a tungsten heavy alloy with good strength and sufficient ductility, as it is softer and more ductile than tungsten. Up to 8 wt% addition results in a unique combination of good tensile strength and ductility. A further increase in the content leads to a further drop in the ductility of the alloy. The drop in percentage elongation can be controlled with the use of a 8/2 Ni/Fe ratio in the alloy [63]. The Mo doping decreases the melting point of the tungsten heavy alloy and yields fine grains. The important factors that have to be controlled while processing W–Ni–Fe-Mo alloys are the duration of the isothermal sintering hold and the cooling rate. A higher sintering hold duration and a slow cooling rate lead to the formation of intermetallic phases and a drop in the mechanical properties of the alloy. The oxide dispersion of yttrium or lanthanum is used to reduce the segregation of impurities on the tungsten–matrix interface by forming stable compounds. Better results are possible with a lower percentage of oxide dispersion. When the rare earth oxide content is very high, the remaining oxides after the formation of compounds re-precipitate in the tungsten–matrix interface. This prevents the migration and diffusion of atoms during liquid-phase sintering of the alloy, leading to a lower density. To overcome this drawback, the sintering time has to be increased. However, this may lead to an increase in the tungsten grain size. Hence, optimum use of the oxide content is necessary to get the desired properties of the alloy. At high temperatures, the tensile strength and compression strength get increased with the oxide dispersion technique. In the application of armor plate piercing penetrators, the material should have self-sharpening susceptibility during deformation at high strain rates. The mechanically alloyed yttrium-oxide-dispersed tungsten heavy alloy was found to satisfy the penetration requirement as experimented with and patented by Hong et al. [94]. The amount of tungsten should be maintained at 90 wt% and above to get a high-density penetrator of more than 17 g/cm3 [83]. The oxide- dispersed alloy showed a larger piercing depth per density compared with the undoped tungsten heavy alloy of W–Ni–Fe. The addition of yttrium is more effective in maintaining the ductility of the alloy compared with the lanthanum oxide dispersion. The brittle nature of lanthanum reduces the percentage elongation with an increase in the content of the oxide dispersion. However, it is more effective at controlling the phosphorous content in the alloy. When the content of P is higher in the alloy, the impact strength is reduced. The La addition effectively reduces this detrimental effect and enables the impact strength to increase with an increase in La content. Experiments were also performed with the addition of Al2O3, but the results were not promising. It did not show any improvement in the mechanical properties of the alloy. Instead, it resulted in a 15% reduction in the tensile strength and a huge reduction (from 21% to 3%) in elongation compared with the undoped alloy of 93W–4.9Ni–2.1Fe [95]. More pores were visible in the doped alloy, which showed a good compression strength at an elevated temperature as is usually seen for oxide-dispersed alloys [80]. The discussions lead to the following conclusions: • The strength and hardness of tungsten heavy alloys depend on the bonding strength of the W–matrix interface. A W–Ni–Fe alloy with good strength is made possible with the addition of rhenium and molybdenum elements. • The correlation between the microstructural parameters and mechanical properties shows that a smaller grain size is an effective factor in improving the strength and ductility of the tungsten heavy alloy. The drop in ductility in a molybdenum-added heavy alloy can be controlled to some extent with the use of a 8/2 ratio of Ni/Fe. • The oxide dispersion of yttrium with W–Ni–Fe is found to be more effective in ob- taining an alloy with good strength and ductility compared with a lanthanum oxide dispersion. A fine-grained alloy with yttrium dispersion leads to a microstructure that can promote adiabatic shear banding, which is a necessary criterion for kinetic energy penetrator applications. • Processing techniques like spark plasma sintering are observed to produce tungsten heavy alloys with higher yield and tensile strength. The optimum sintering tempera- Materials 2021, 14, 1660 17 of 20

ture and time are also important factors to be controlled in obtaining an alloy with specific mechanical properties. • Developments in processing methods like additive manufacturing techniques will help to improve the alloying techniques with tungsten heavy alloys and to produce complex net-shaped parts with higher strength.

Author Contributions: Conceptualization, S.N. and R.A.A.R.; methodology & investigation, S.N. and R.A.A.R.; resources, S.N.; data curation, R.A.A.R.; writing—original draft preparation, S.N.; writing—review and editing, V.G.; R.A.A.R. and C.-P.J.; visualization, V.G.; supervision, R.A.A.R.; project administration, R.A.A.R. and C.-P.J.; funding acquisition, C.-P.J. All authors have read and agreed to the published version of the manuscript. Funding: This research was funded by Ministry of Science and Technology of the Republic of China (Taiwan), under grant numbers MOST 107-2221-E-194-024-MY3 and MOST 109-2221-E-194-011-MY2. Institutional Review Board Statement: Not applicable. Informed Consent Statement: Not applicable. Data Availability Statement: The data presented in this study are available on request from the corresponding author after obtaining permission of authorized person. Conflicts of Interest: The authors declare no conflict of interest.

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