Composite substitutes for lead
Lech Paszkowski, Zbigniew Ludyński, Dionizy Biało, Waldemar Wiśniewski
Quarterly No. 1, 2010 pages 20-24
DOI:
keywords: composite, heavy alloy, polymer, powder metallurgy
abstract In the work, research has been taken up on the problem of lead elimination from presently very popular technical applications, through elaboration of its substitutes. It is a problem of utmost importance given the harmful impact of lead on living organisms and the international regulations in force setting out approaching deadlines for total elimination of lead use. Lead has been included in the group of the most toxic substances. Very promising group of materials in the works on an environmentally-friendly substitute for lead pertains to materials of composite structure. One important component of such a composite is a powder having high density, for instance, made of tungsten or its alloys, or tungsten carbides. The second component is composite matrix, most frequently a polymer. The appropriate material selection of composite components, and particularly the proportion of both the components, enables the attainment the assumed density of composites, varying over a wide range. The work pertains to elaboration of technology of the materials having a composite structure, containing powder of so called heavy alloy (WHA) having a content of 93%W+5%Ni+2%Fe and polymer or metal matrix. This kind of heavy alloy is traditionally used to manufacture projectile cores. The powder is produced from chips using the impact method. Its price is more than three times lower than that of the tungsten powder, or the original powder of heavy alloy. The basic task was solved in two variants, using as a matrix: Epidian type thermosetting resin and metallic bonding - tin. Two different manufacturing processes of the composites was proposed. In the first, composite granulate was pressed in the die at pressure of 50÷600 MPa and its polymeric matrix was hardened at temperature of 180°C. In the second process, mixture of WHA and tin powders was pressed in the die at pressure of 600 MPa and next compacts was sintered at 280°C. For each of the variants tests were conducted on the influence of powder content and matrix, as well as of the influence of forming conditions on density of attained composites and their selected mechanical properties. It has been proven, that there exists a possibility of such selection of material content and of such a manufacturing pro-cess, as to attain the densities of composites matching the density of lead - 11.3 Mg/m3. The results of metallographic tests of attained composites were presented. Additionally and F-Rockwell hardness of the composites were established.