Tungsten

In its raw form, tungsten is a hard steel-grey metal that is often brittle and hard to work. If made very pure, tungsten retains its hardness (which exceeds that of many steels), and becomes malleable enough that it can be worked easily. It is worked by forging, drawing, or extruding but it is more commonly formed by sintering. Of all metals in pure form, tungsten has the highest melting point (3,422 °C, 6,192 °F), lowest vapor pressure (at temperatures above 1,650 °C, 3,000 °F), and the highest tensile strength. Although carbon remains solid at higher temperatures than tungsten, carbon sublimes at atmospheric pressure instead of melting, so it has no melting point. Tungsten has the lowest coefficient of thermal expansion of any pure metal. The low thermal expansion and high melting point and tensile strength of tungsten originate from strong metallic bonds formed between tungsten atoms by the 5d electrons. Alloying small quantities of tungsten with steel greatly increases its toughness. Tungsten exists in two major crystalline forms: α and β. The former has a body-centered cubic structure and is the more stable form. The structure of the β phase is called A15 cubic; it is metastable, but can coexist with the α phase at ambient conditions owing to non-equilibrium synthesis or stabilization by impurities. Contrary to the α phase which crystallizes in isometric grains, the β form exhibits a columnar habit. The α phase has one third of the electrical resistivity and a much lower superconducting transition temperature TC relative to the β phase: ca. 0.015 K vs. 1–4 K; mixing the two phases allows obtaining intermediate TC values. The TC value can also be raised by alloying tungsten with another metal (e.g. 7.9 K for W-Tc). Such tungsten alloys are sometimes used in low-temperature superconducting circuits.

Tungsten is found mainly in the minerals wolframite (iron–manganese tungstate (Fe,Mn)WO4, which is a solid solution of the two minerals ferberite FeWO4, and hübnerite MnWO4) and scheelite (calcium tungstate (CaWO4). Other tungsten minerals range in their level of abundance from moderate to very rare, and have almost no economical value.

Approximately half of the tungsten is consumed for the production of hard materials – namely tungsten carbide – with the remaining major use being in alloys and steels. Less than 10% is used in other chemical compounds. Because of the high ductile-brittle transition temperature of tungsten, its products are conventionally manufactured through powder metallurgy, spark plasma sintering, chemical vapor deposition, hot isostatic pressing, and thermoplastic routes. A more flexible manufacturing alternative is selective laser melting, which is a form of 3D printing and allows creating complex three-dimensional shapes.