W-MMC

Tungsten-based
metal matrix composites

The basis of intelligent technology
Plansee is the world’s leading manufacturer of powder-metallurgically processed refractory and specialty metals. Based on
our core competencies in the areas of high-performance materials, forward-looking applications, and technologies, we have
manufactured products and components made from molybdenum, tungsten, tantalum, niobium, chromium and their alloys for
100 years.
Being a leader in technological innovation, we consistently strive to optimize materials and meet new mechanical, chemical andphysical demands that arise from our clients’ practical needs.

2Contents
Tungsten-based metal matrix composites

Page

Overwiev

4

Range of materials for standard products

6

Guidelines for material selection

7

Available products and standard dimensions

10

Production process

11

Machining of W-based MMC

15

Physical and mechanical properties, corrosion behavior- Properties of DENSIMET ® and INERMET ®

DIS CLAIM ER- Properties of DENAL

®

17
19

- Properties of WCu / SPARKAL ®

21

Other Plansee high-performance materials

22

Conversion units

23

The contents of this brochure are for general information purposes only. All information contained in this brochure, e.g. regarding
quality, material properties and purpose of use, are provided only as a courtesy and does not constitute legally binding advice.
Plansee expressly disclaims any warranty, either express or implied, and liability, in particular with respect to the accuracy, completeness or suitability of the information, its freedom from errors or that the information is free and clear of third-party rights.
All rights reserved. Text, images and graphics as well as their arrangement are subject to copyright protection and otherprotective laws. The content of this brochure may not be copied, distributed, modified or made accessible to third parties forcommercial purposes.

3O ve r vi ew of Pl a n s e e ’s W-MM C(Tungsten-based metal matrix composites)
Tungsten is considered a refractory metal. It has the highest melting point and the lowest vapor pressure of all metallic elements. It is also characterized by high density, a very high level of dimensional stability, and a uniquely low coefficient of thermal
expansion.
Plansee specifically influences and complements these special properties of tungsten by combining it with other metals. The
results are tungsten-based metal matrix composite materials, including tungsten heavy alloys (WHA) and tungsten copper
composites, with unique properties: DENSIMET®, INERMET®, DENAL®, WCu and SPARKAL®.

W-MMCTUNGSTEN HEAVY ALLOYS(WHA)

Densimet®

(weakly ferromagnetic)

Inermet®

(paramagnetic)

Aluminum Casting
Balancing and Vibration Weights
Shieldings

Figure 1: Material overview

4

TUNGSTEN COPPER MATERIALS(WCu)

Denal®

Infiltrated

Products andComponents for
Aerospace& Defense

Electrical Contacts
Heat Sinks
Jet Vanes and Nozzles

Back-casted
Electrical Contacts
Plasma Nozzles
Stationary Anodes
Welding Electrodes

Tungsten-based metal matrix composites offer a perfect combination of high densities and mechanical properties. A huge ad-

Tensile Strength [N/mm²]

vantage is their good machinability.
2500

Tungsten

Steels2000

Molybdenum
alloysTantalumalloys1500

Niobiumalloys1000
DENSIMET®
INERMET®
DENAL®

500

WCu
SPARKAL®

Copper0

Lead alloys
6

8

10

12

14

16

18

20

Density p [g/cm³]
Figure 2: Strength of materials

Customized solutions and R&D support
We produce our tungsten-based metal matrix composite materials by powder metallurgical processes. This technology gives
us the flexibility to specifically adapt the microstructure of the materials during the manufacturing process. As a result, we can
supply materials whose properties are optimized to the customer's specific applications. Additionally, a wide range of material
compositions is possible, such as the production of the contact material tungsten carbide-copper (WCCu).
An experienced team of research and development experts at several locations works with our customers on customized
solutions. We simulate the behavior of materials in manufacturing and application processes, research the chemical and physicalprocesses, and test our findings in specific trials in close coordination with our customers. Our R&D center is fully integrated
within our production operation and guarantees maximum flexibility and efficiency. Together we are capable of responding toour customers’ individual needs and meeting their ever-increasing requirements.
Our mission is to remain one step ahead in the development of the highest quality materials and to offer our customers realcompetitive advantages.

5

Range of materials for standard products
Material

Designation

Chemical composition [%]W
Remainder

Nominaldensity

ASTM-B-777/07
Class

Weakly ferromagnetic
DENSIMET® 170

D170

90

Ni, Fe17.0

1

DENSIMET® 176

D176

92.5

Ni, Fe17.6

2

DENSIMET® 180

D180

95

Ni, Fe18.0

3

DENSIMET® 185

D185

97

Ni, Fe18.5

4

DENSIMET® 188

D188

98.5

Ni, Fe18.8

DENSIMET® D2M

D2M

90

Ni, Mo, Fe

17.3

INERMET® 170

IT170

90

Ni,Cu

17.0

1

INERMET® 176

IT176

92.5

Ni,Cu

17.6

2

INERMET® 180

IT180

95

Ni,Cu

18.0

3

DENAL®

high characteristics swaged

92

Ni, Fe, Co

17.6

DENAL®

high characteristics swaged,
Co-free

91.7

Ni, Fe

17.55

DENAL®

high characteristics

91

Ni, Co

17.5

WCu

WCu10

90

Cu, (Ni)

17.1

WCu

WCu15

85

Cu, (Ni)

16.4

WCu

WCu20

80

Cu, (Ni)

15.5

SPARKAL®

SPARKAL® X

75

Cu

14.8

SPARKAL®

SPARKAL® X FIN

80

Cu, Ni

15.6

Paramagnetic

In addition to the standard materials listed above, we offer a wide range of customized materials.
Our material experts would be pleased to assist you and develop the optimal material
combination for your particular requirements.

6

Guidelines for material selection
Correct material selection requires knowledge of the application. Important criteria may be:
Physical properties
		(e.g. density, shielding behavior against radiation, thermal conductivity, thermal expansion coefficient, melting point,		electrical conductivity, burn-off resistance, magnetization)
Mechanical properties

		(e.g. strength, fracture toughness, elongation, creep behaviour)
Chemical properties		(corrosion and oxidation resistance)
Ease of working

		(machinability, formability, weldability)

With suitable material compositions and manufacturing processes, a variety of properties can be achieved based on tungsten.

Material properties

highdensityshieldingbehavior against
radiation

goodmachinability

very goodmechanical properties
as strengthand elongation

excellent corrosion
and oxidation
resistance

Figure 3: Properties of W-MMC

7

Plansee has developed several different composite materials with various property profiles. Each material features a special
combination of properties and is therefore unique and unlike any other material. The advantages of our most frequently usedmaterials are:DENSIMET® and INERMET®
Plansee DENSIMET® and INERMET® composite materials are tungsten heavy alloys with a high tungsten content (> 90%) anda NiFe or NiCu binder phase. DENSIMET® and INERMET® tungsten alloys are distinguished by their particularly high density.
Combined with their ability to absorb radiation as well as their outstanding mechanical properties and machinability, they are
the ideal materials for a wide range of applications, such as in the aerospace field, the automotive industry, medical engineeringand the construction industry.
Densimet® and Inermet® exhibit the following properties:
High density of 17.0 to 18.8 g/cm3 (similar to pure tungsten)
Better machinability compared to pure tungsten
Inexpensive manufacture of complex products and components
High Young’s modulus and excellent mechanical properties
High absorption capacity for X-rays and gamma rays
Safe in terms of health and environment
DENSIMET® alloys also offer excellent strength and ductility, while another clear advantage of INERMET® lies in its
non-magnetic characteristics.

8

DENAL®
DENAL® is the brand name used for defense-related products. DENAL® is usually a customized material with a very highcompromise between high strength and ductility for various applications such as penetrator materials for penetration requirements.

WCu and SPARKAL®
Tungsten-copper combines a high level of temperature resistance – one of tungsten’s most important benefits – with theexcellent electrical and thermal conductivity of copper.
WCu exhibits the following properties:
Excellent arc resistance
Outstanding electrical conductivity
High strength
Good machinability
Very good thermal conductivity
Low thermal expansion
Due to the special composition of the chemical ratio, properties can be optimized according to requirements in terms of electricalconductivity, thermal conductivity, coefficient of thermal expansion and burn-off rate. One of these special compositions is theSPARKAL® – material – developed to meet the requirements of electrical discharge machining (EDM), SPARKAL® electrodes offer
a number of advantages over conventional electrode materials.

9

Available products and standard dimensions
We offer standard products from stock in our Plansee Online-Shop. Please contact us for other dimensions and individual
geometries. We will be pleased to help.

DENSIMET ® D176
Rods

Ø 6 – 62 mm

Length: 320 – 700 mm

SPARKAL ® X
RodsØ 8 – 90 mm

Length: 230 – 350 mm

Square bars

Ø 8 × 8 – 50 × 50 mm

Length: 350 mm

Plates

3 × 75 – 25 × 75 mm(thickness × width)

Length: 350 mm

SPARKAL ® X FIN
Tubes

Ø 0.5 – 6 mm

Length: 175 mm

Rods

Ø 0.5 – 6 mm

Length: 175 mm

We like to make life easy:
A quick and simple ordering process and clearly outlined pricing – directly on yourscreen. Rods, bars, blocks, tubes and plates as well as other Plansee products
are available in configurable dimensions at www.plansee.com/shop
For more dimensions or customized products to meet your special needs – please
visit www.plansee.com or contact us directly at support@plansee.com. Our
sales team is looking forward to hearing from you.

10

Production process
Plansee products made from tungsten-based MMC are manufactured using powder metallurgy. All stages of production, fromthe powder to the finished product, satisfy Plansee’s quality standards, exceeding ISO 9001 requirements.

Production process of tungsten heavy alloys
In order to manufacture DENSIMET® and INERMET®, mixtures of powdered metals are pressed and liquid-phase sintered toobtain a dense and solid material. The sintered product can be supplied as a semi-finished product such as plates and rods,
as a near-net-shape product, or as a finished product according to the customer’s drawings. If desired, our DENSIMET® and
INERMET® components can undergo shaping and heat-treatment techniques to meet specific application requirements.
Plansee DENSIMET® and INERMET® materials comply with the AMS-T-21014, the AMS 7725 rev E, and the ASTM-B-777-99(MIL-T-21014) specifications.

Powder
Raw Materials

Pressing(Mechanical, Isostatic or Extrusion)

Sintering andHeat Treatment

Machining

Products

Finished

Semi-finished

Netshape

Figure 4: Manufacturing process of DENSIMET® and INTERMET® products

DENAL® is an advanced range of tungsten heavy alloys suited for kinetic energy ammunition penetrators. It is produced ina specific manufacturing process that includes forging, which allows the material to reach very high levels of mechanicalcharacteristics. DENAL® is available in the form of round bars in several different lengths and diameters, which directly influences
the penetration properties against targets. Suitable for medium and large caliber ammunition specifications, DENAL® is alsoavailable in a Co-free version, which takes into account environmental conditions from certain customers. DENAL® mechanicalproperties can be adapted to customer specifications, creating the best compromise between industrial efficiency and resistance to extreme conditions in a single product.

11

Production process of WCu materials
WCu materials are also manufactured from metal powder. All stages of production from the powder all the way to the finishedproduct are carried out in-house and all satisfy Plansee’s quality standards, which exceed the provisions of ISO 9001:2000 and
AS/EN/JISQ 9100.

The essential step of manufacturing WCu products, such as SPARKAL® EDM electrodes, is infiltration:
During a two-stage manufacturing process, first a porous sintered base is fproduced from tungsten, and then the open pores are
infiltrated with the liquefied copper. After sintering, the product can be machined to individual customer requirements.
This approach, leaves the properties of the individual components unchanged. An inspection under the microscope verifies that,the properties of each of the components main intact. At the macroscopic level, however, the properties of the individual components are combined. For example, the new material may have modified thermal conductivity and thermal expansion values.

Powder
Raw Materials

Pressing(Mechanical, Isostatic or Extrusion)

Sintering
Infiltration or Back-casting

Machining

Products

W
Cu

Figure 5: Schematic representation of the manufacturing process of WCu products and SPARKAL®

Another production approach is back-casting:
Back-cast materials simultaneously combine the material properties of two different material components. During this process,the materials themselves are retained in their original state and are only bound at a thin junction. The metals are fused in a moldto form a bond measuring just a few microns. Unlike welding and soldering techniques, this method guarantees a 100 % connection and ensures optimal thermal conduction.

12

Creating the future responsibly – since 1921
As early as 1921, Plansee chose to specialize in the powder metallurgical production of refractory metals – a recognized green
technology.
When we produce and process our materials, we strive to minimize the impact on theenvironment. We are always mindful of material utilization, energy consumption, andemissions. Our near-net-shape manufacturing process, allows us to achieve high output.
This results in lower waste and saves resources.
The standards we adhere to are summarized in our Environmental and Quality Guidelines.

Raw materials from conflict-free sources
As one of the world's leading manufacturers of refractory metals, we bear great responsibility. We are especially concerned thatthe raw materials we procure are sourced responsibly and exclusively from conflict-free sources. As a result, we go to great
lengths to ensure that we do not source or use any raw materials from socially, ethically or ecologically questionable sources.
Sustainability is a constant watchword in our purchasing policy. We only select suppliers that comply with rigorous procurement
guidelines and our Supplier Policy.
Suppliers not only have to demonstrate that raw materials meet our strict quality requirements. They must also unreservedly
respect human rights, labor laws, and international trade law, and provide proof that their raw materials come from "conflictfree" sources and meet strict environmental requirements. We participated in a pilot study conducted by the Organization for
Economic Cooperation and Development (OECD) and have implemented the "Due Diligence Guidance for Responsible Supply
Chains of Minerals from Conflict-Affected and High-Risk Areas“.
In its audit, the audit committee of the Responsible Business Alliance (RBA) and the Global e-Sustainability Initiative (GeSI) confirmed that Global Tungsten & Powders (GTP) in Towanda - a Plansee Group company – sources tungsten in compliance with
the Responsible Minerals Assurance Process (RMAP). For Plansee's customers, the certificate provides independent proof that
the Plansee Group procures its tungsten from responsible sources.

13

Consistent recycling throughout the entire process
Plansee attaches great importance to using resources as sparingly as possible throughout the production process. Near-netshape production therefore plays a crucial role. Still, production waste and return materials cannot be completely avoided. These
are chemically and thermomechanically processed for reuse in the company's own recycling facilities.
At the same time, the environment is not the only consideration. There are also good economic reasons for re-using these socalled "secondary raw materials":	Security of supply	Careful use of natural resources
Our in-house team of scientists is constantly fine-tuning the adopted methods and processes
and ensures that only top-quality powder is obtained. In the case of tungsten, in particular,a large proportion of the material requirements is covered by recycling. The input material to
the recovery process consists of sintered hard tungsten carbide scrap as well as soft scrap
such as powders and grinding sludge, and other secondary raw materials with a tungsten
content of 60 % or more. To enable us to reprocess as much waste material as possible, wehave long-term take-back agreements with many of our customers.

14

Machining of W-based MMC
Machining of DENSIMET® and INERMET®
Turning
Tools

CERATIZIT Maxilock S / CERATIZIT Maxilock N

Indexable inserts
H 216 T / H 10 T / AMZ / H 210 T

Code −23P / −25P / −25Q / −27 / −42
positive cutting geometry, sharp cutting edges

Cutting speed [m/min]

60 – 140

Feed [mm]0.05 – 0.3

Cutting depth [mm]≤6

Coolant

Emulsion
Use CERATIZIT milling tool systems Maximill and solid carbide end mill cutter
with positive cutting edges of the following geometry:

Rake angle
Front clearance
Hard metal grade+10° – +25°
0° – +15°
H 216 T / H 10 T / AMZ

End mills micrograin K10 uncoated

DIN 2535

Cutting speed [m/min]

70 – 150

Feed/Tooth [mm]0.03 – 0.15

Coolant

Dry
Drilling

Hard metal gradeFinest grain K10 uncoated

Drilling diameter< 18 mmDrill

HSS or CERATIZIT solid carbide twist drill

Cutting speed [m/min]

HM: ≥ 30 / HSS: 8 – 15

Drilling diameter≥ 18 mm

Drill

Short hole drill

Cutting speed [m/min]

HM: 30 – 60

Indexable inserts

WCGT Grade CTWN415 / XOMT Grade SR226

Cutting speed [m/min]

30 – 60

Feed [mm]0.03 – 0.1

Coolant

Emulsion
Tapping

Tools

VA nitrided taps with straight flutes and a tensile
strength of 1400 N/mm2

Coolant

Cutting oil

15

Machining of WCu
Milling
Hardmetal grade

ISO K10-K20 / H216T / H10T; TiN coating possible

Tools

End milling cutter K10; DIN 2535HB, uncoatedRake angle

8° – 12°

Clearance angle

7° – 12°

Approach angle of the main cutting edge

45°

Cutting speed

80 – 100 m/min

Feed0.03 – 0.15 mm/rev

Condition of machining

Emulsion
Grinding

Centerless grinding

Grinding wheels made of corundum in the hardness K, L, M

Grain

40 – 60 with intermediate structure

BinderResine binder

Cutting speed

28 – 32 m/sec.

Infeed0.02 – 0.1 max.

Lubrication

Emulsion
Drilling
Through holes

DrillHigh speed steel with Co (8%)

Tip angle

120° – 130°

Clearance angle at the main cutting edge

10°

Clearance angle at the periphery

8° – 10°

Cutting speed

12 – 20 m/min

Lubrication

Emulsion
Counter bores

Drill

Hardmetal (grade ISO K10-K20)

Tooling geometry

as for high speed steel

Cutting speed

35 – 40 m/min

Lubrication

Emulsion

Coolant

Emulsion
Tapping

16

Hardmetal grade

ISO K10-K20 / H216T / H10T / TSM20 / AMZ

Tools

Maxilock S/NInserts

Code −23P / −25Q / −27 / −42

Rake angle

6 – 8°

Clearance angle

7°

Cutting speed

60 – 100 m/min depends on dimension of the electrodeFeed

0.05 – 0.3 mm/rev

Lubrication

EmulsionPhysical and mechanical properties,
corrosion behavior
Properties of DENSIMET® and INERMET®:
Physical properties – typical values

Coefficient of thermal expansion INERMET®

Coefficient of thermal expansion DENSIMET®

Thermal conductivity DENSIMET® and INERMETElectrical resistivity DENSIMET® and INERMET®

Mechanical properties – typical values

D170

IT170

D176/W

IT176

D180

IT180

D185

Young’s modulus E [GPa]

340

330

360

350

380

360

385

Modulus of rigidity G [GPa]

140

125

145

135

150

140

160

17

18

Yield Strength DENSIMET® and INERMET®

Tensile Strength DENSIMET® and INERMET®

Hardness HV10 DENSIMET® and INERMET®

Hardness HB30 DENSIMET® and INERMET®

Elongation at fracture DENSIMET® and INERMET®

Compressive Strength DENSIMET® and INERMET®

Properties of DENAL®

Material

Density

Y 0.2
Yield strength[MPa]
Av. / Min.

UTS
Tensile strength[MPa]
Av. / Min.

A%
Elongation[%]
Av. / Min.

K (5x5)Charpy test
[J/cm 2]
Av. / Min.

DENAL® - high characteristics swaged
DENAL®
920 60 20

17.61250 / 1180

1250 / 1180

14 / 9100 / 60

DENAL®
920 159 20

17.61460 / 1400

1460 / 1400

11 / 8150 / 100

DENAL®
910 179 20

17.51640 / 1600

1640 / 1600

10 / 7

100 / 60

DENAL®
910 XXX 2017.51800 / 1720

1800 / 1720

4-

DENAL® - high characteristics swaged, Co-free
DENAL®
917 108 XXX (1)17.55

1280 / 1220

1315 / 1255

12 / 8.5

170 / 105

DENAL®
917 108 XXX (2)17.55

1410 / 1350

1435 / 1375

9/6

90 / 50

DENAL®
917 108 XXX (3)17.55

1510 / 1450

1525 / 1465

7/4

60 / 30

DENAL® - high characteristics
DENAL®
900-120-25

17.2

700

1000

35

300

DENAL®
920-120-25

17.6

720

1030

29

150

19

UTS Tensile strength of DENAL® (average values)

20Properties of WCu
Physical and mechanical properties – typical values

Material[wt%]

Density at 20°C
[g/cm³]

CTE at 20°C
[ppm/K]TC at 20°C
[W/mK]

WCu10

17.1

6.4

195

WCu15

16.4

7.3

215

WCu20

15.5

8.3

235

Properties of SPARKAL®
Physical and mechanical properties - typical values depending on geometry and product dimensions

SPARKAL ® X

SPARKAL ® X FIN

Chemical composition (%)

W 75
Cu 25

W 80
CuNi 20

Density (g/cm3)

14.8

15.6

Hardness (HV 5)

240

270

Electrical conductivity (% IACS)

40

20

Electrical resistance (µΩ cm²/cm)

4.3

8.4

250.000

280.000

Modulus of elasticity (MPa)21

O th e r P l a n s ee h i gh-p e r f o r m an ce m ate r ials
Based on our many years of experience in the field of powder metallurgy, we supply a wide range of products made from highperformance materials. In addition to tungsten-based metal matrix composites, Plansee is also a leading producer of:
Molybdenum and Mo alloys
Tungsten and W alloys
Tantalum and Ta alloys
Copper-Chromium
Niobium
Sputter materials for hard coating

Selection of Plansee products made of high-performance materials:

22

Sputtering targets

Semiconductor base plates

CuCr contacts

Glass melting electrodes

Wires for the lighting industry

Various finish types of X-ray rotary anodes

10
15

Conversion of units

20
25
30

Table 1035

Property

SI UnitAreamDensity

Conversation factor

2

kg/m

3

J = N•m

Energy

= W•s

Force

N = kg • m/s2

Length

m

Mass

kg

Power

W = J/s

Pressure (Stress)

Pa = N/m2

Specific heatby mass

J (kg • K)

Temperature

40
45

1 in²

= 6.4516 • 10-4 m²

1 ft²= 9.2903 • 10-2 m²

1 lb/in³= 2.76799 • 10 kg/m³

1 lb/ft³= 16.0185 kg/m³

1 Btu= 1.05506 • 10 J

1 cal

= 4.184 J

1 eV= 1.6022 • 10-19 J

1 lbf= 4.4482 N

50
55
60

4

65
70

3

75
80
85
90
95
100

1 in

= 2.54 • 10-2 m

1 ft= 3.048 • 10 m

1 lb

= 4.5359 • 10-1 kg

1 Btu/hr= 2.93071 • 10-1 W

1 hp= 7.457 • 102 W

1 atm= 1.01325 • 105 Pa

1 lbf/in² (psi)= 6.89476 • 103 Pa

1 lbf/ft²= 47.8803 Pa

1 mbar= 10 Pa

1 N/mm² (MPa)= 106 Pa

1 torr

= 1.33322 • 102 Pa

1 cal/(g • °C)= 4.1868 • 10³ J/(kg • K)

1 Btu/(lb • °F)= 4.1868 • 103 J/(kg • K)

105
110

-1

115
120
125
130
135
140
145
150
155

2

160
165
170
175
180
185
190

x °C = (x + 273.15) K

195

y °F = (y • 0.5556 + 255.37) K

200°F in °C: (°F – 32) • 5/9 = °C

210

°C in °F: (°C • 9/5) + 32 = °F

215

205

K (Kelvin)

Thermal conductivity

W/(m • K)

Volumem3

220

1 kcal/(m • hr • °C)= 1.163 W/(m • K)

1 Btu/(ft • hr • °F)= 1.73073 W/(m • K)

1 in³

= 1.63871 • 10-5 m³

1 ft³= 2.83168 • 10 m³

225
230
235
240

-2

245
250

°F 32

200

400

°C 0

100

200

600
300

800
400

1000
500

1200
600

1400
700

800

1600
900

1800
1000

2000

2200

1100

1200

2400
1300

255

2600
1400

260

1500

265
270
275

For further information on Plansee semi-finished products and formed parts made of Mo and280

Mo alloys, please visit our website www.plansee.com or contact your Plansee partner.
23

Close to the customer – our global network
Plansee manufactures and markets its products worldwide. Production sites in Europe, the USA, Japan, India, China, and Korea
as well as a global network of sales subsidiaries and sales partners enable outstanding customer service and product quality
delivered by local teams. Stronger than any alliance and more diversified than single producers, Plansee is the most reliable
source for high-performance components made of refractory metals.

For more information and local contacts, please visit our website:www.plansee.com

Plansee SE
Metallwerk-Plansee-Str. 71
6600 Reutte
Austria
Telephone: +43 5672 600 0
E-Mail: info@plansee.com
We reserve the right to make technical changes for improvement of the product.
Edition: 08.2023

Part of the Plansee GroupQM1 / HPM-070-TD-024 / part 100 / Version 03