Process Parameter Optimization and Improved Properties of Large Electric Current-Sintered Mo-W-Cu Alloys Using Orthogonal Analysis

Mo-W-Cu alloys show great potential for high-temperature applications, while their conventional fabrication often involves elevated sintering temperatures and extended sintering durations. In this work, we employed a rapid and efficient method to fabricate Mo-W-Cu alloys by large current electric field sintering (LCS). We investigated the effects of four factors (ball-milling time, sintering time, sintering temperature, and pressure) on the microstructure and properties of the alloys using orthogonal experiments. We found that sintering temperature exerted the most significant influence on densification and hardness, followed by pressure, ball-milling time, and sintering time. For electrical resistivity, sintering temperature emerged as the most critical factor, followed by ball-milling time, pressure, and sintering time. The optimal conditions were 20 h of ball milling and 6 min of sintering at 980°C and 30 MPa, resulting in a relative density of about 98%. Apart from the Mo, W, and Cu phases, the alloys contained three new phases (Cu 0.4 W 0.6 , Mo-Cu, and Mo-W solid solutions) that were not in the equilibrium state. Furthermore, we discuss the sintering behavior of the LCS-fabricated Mo-W-Cu alloys, offering insights into the subsequent preparation and theoretical exploration of Mo-based materials.