Porous tungsten with controlled porosity by low temperature sintering

Porous tungsten as a high current density cathode is one of the important applications of the metal, which is mostly used in high temperature conditions due to its exceptional resistance to melting (T m = 3410±20°C). Its porous form has been a crucial component of dispenser cathodes used in electronic valves and high power lamps. Porous tungsten skeleton forms the matrix, which is then impregnated with an electron emissive compound. Upon every emission from the surface, new material has to be fed into the surface pores via the open pore channels. Hence it may be proposed that a uniform porosity is needed for a better performance. However, a controlled porosity has not been achieved yet. Moreover, sintering of tungsten has always been difficult due to the extreme process conditions. A high sintering temperature (T s ≥2000°C) and a strong reductive atmosphere (hydrogen) have been the absolute necessity in making these parts. This study further explores an alternative sintering technique being developed. The idea is based on the reactive sintering concept. The energy output from the exothermic reactive system of tungsten oxide and aluminium has been the heat source for sintering porous tungsten. As a result, sintering temperature and time have been reduced considerably. Higher homogeneity, thus more uniform pore distribution, was observed. A better control of porosity related to the pressing and sintering conditions was achieved by the characterisation method previously developed. Microhardness has been a useful monitor of the scatter in porosity of the parts. Throughout the study, SEM was used to observe the porous structures and powder morphologies. DSC and XRD were useful to follow the microstructural evolution in the reactive system.