2026 Chattopadhyay Tungsten Heavy Alloy Powders

This paper investigates the Electrode Induction Gas Atomization (EIGA) of a Class 4 tungsten heavy alloy (WHA-4) containing 97.8 wt.% W, with the balance comprising Ni and Fe. Compared with conventional tungsten heavy alloys containing less than 95 wt.% W, the high tungsten content reduces the liquid-phase fraction and melt fluidity, making stable processing significantly more challenging. Powder-metallurgy-fabricated electrodes were atomized under varying resonant induction conditions to evaluate the effects of capacitance, frequency, and input power on melt stability. The results show that stable processing can be achieved through an optimum combination of capacitance and resonant frequency, providing sufficient energy to maintain a steady melt stream and uninterrupted atomization. Under optimized conditions, predominantly spherical powders with minimal defects were successfully produced. Microstructural characterization revealed that the Ni–Fe binder phase remained localized along tungsten grain boundaries and in isolated pockets between tungsten grains. X-ray diffraction and chemical analyses confirmed that the phase constitution and alloy composition of the electrode were preserved during atomization. Under non-optimum conditions, process instability was associated with incomplete melting, beard formation, unstable melt flow, and nozzle blockage. These findings provide new insights into the atomization behavior of high-tungsten heavy alloys and establish practical processing procedures for producing high-quality WHA-4 during densification.