Tungsten rod: starting material for the pre-crushing of tungsten

Wolfram scrap metal pre-crushed – material preparation for fine grinding

Production of metal powder from tungsten: reduction, classification and powder characterization

Production of tungsten powder from APT and tungsten oxide for pressing, sintering and additive manufacturing

Tungsten powder is a key raw material for powder metallurgy components, hard metal precursors, thermal spray coatings, and specialized high-temperature applications. Industrially, tungsten metal powder is typically produced from chemical precursors such as ammonium paratungstate (APT) and tungsten oxides. Crucial factors include purity, controlled hydrogen reduction, a defined particle size distribution, and reproducible properties such as bulk density and flow behavior.

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Objectives of tungsten powder production

The production of tungsten powder focuses not only on converting a chemical precursor into metallic tungsten, but above all on precisely tailoring application-specific powder properties. Key parameters include particle size and size distribution, morphology, bulk density, flow behavior, and purity. These factors influence the powder's processability and determine its suitability for pressing and sintering processes, thermal spraying, or additive manufacturing.

Tungsten powder production - measuring tape for comparing current size

Material data on tungsten and its precurs

Tungsten is a refractory metal with a very high density and a very high melting point. For powder production, APT (a specific atomization process), tungsten oxides, purity, subsequent powder morphology, and particle size distribution are particularly relevant.

Property	Value
Material name	Tungsten / Tungsten powder
Synonyms	Tungsten, W, tungsten metal powder
Chemical symbol	W
ordinal	74
Typical precursors	Ammonium paratungstate (APT), tungsten oxide, WO3
Dense metal	19,25 g / cm³
Melting point of metal	3420 ° C
Material class	Refractory metal
Process relevance	very high purity requirements, controlled reduction, defined PSD
Typical powder ranges	approximately 0,5 µm to >20 µm depending on the product
Important powder characteristics	Particle size, morphology, apparent density, Hall flow, oxygen content

Typical process for the production of tungsten powder

The process chain ranges from the chemical precursor through thermal conversion and hydrogen reduction to deagglomeration, classification, homogenization and powder testing.

Process step	Objective	Typical machine / method	Typical result
Provide chemical precursor	define high-purity starting material	APT or oxide processing	reproducible pre-stage
Thermal conversion	produce a suitable oxide or intermediate product	Furnace process / calcination	processable tungsten oxide
Hydrogen reduction	produce metallic tungsten powder	Tubular reactor, pusher furnace or rotary kiln	reduced W powder
Desagglomeration	Break down agglomerates and release powders	gentle fine processing	improved dispersibility
Classification	Set a defined particle size distribution	Sieving or air classification	targeted PSD
Homogenization / Sample splitting	Secure a representative powder batch	Mixers, rotary sample dividers, riffle dividers	comparable test sample
Powder test	Evaluate quality and processability	PSD, Hall Flow, Apparent Density, O content	released powder

Typical process parameters for tungsten powder

Important parameters include starting material, reduction atmosphere, target particle size, particle size distribution, apparent density, Hall flow and oxygen content.

Parameter	Typical value / note
Raw material	APT or tungsten oxide
Process atmosphere	reducing, typically hydrogen
Key process	thermal reduction
Typical particle size range	approximately 0,5 µm to >20 µm
AM example D50	20-30 µm
AM example D10/D90	10/40 µm
AM example bulk density	approx. 10 g/cc
AM example Hall Flow	approx. 5-8 s/50 g
Test parameters	PSD, Hall Flow, apparent density, oxygen content
Target variable dependency	Pressing, sintering, injection molding and additive manufacturing require different powder characteristics.

Images of tungsten powder production

Interim result of tungsten pre-crushing – coarse crushing of tungsten carbide

Variants of tungsten powder production

Fine powders for sintering applications

Useful when high packing density, short sintering paths and homogeneous microstructures are required.

More free-flowing powders for pressing and dosing processes

Useful when reproducible filling behavior, bulk density and good process stability are paramount.

Spherical powders for additive manufacturing

Useful when high flowability, defined PSD and uniform layer application are required.

Our machines for tungsten powder production

For tungsten powder, depending on the precursor, target size range and quality requirements, furnace technology for reduction, deagglomeration solutions, classification technology and representative sample division are particularly recommended.

Machine:
More to Jaw crushers

Cost:
Price jaw crusher

Machine:
More about ball mills

Cost:
Price ball mill

Machine:
More about disc vibratory mills

Cost:
Price disc mill

Technical questions regarding tungsten powder production

Use our AI for questions about APT, tungsten oxide, hydrogen reduction, particle size distribution, bulk density and suitable powder preparation.

FAQ on the production of tungsten powder

Tungsten powder is a metallic powder made from the refractory metal tungsten and serves as a starting material for powder metallurgy and thermal applications.

Typically, production involves using APT or tungsten oxide via thermal treatment and reduction in hydrogen, followed by classification and powder testing.

APT and tungsten oxides are the most important industrial precursors for tungsten metal powder.

Depending on the application, typical tungsten powders range from about 0,5 µm to over 20 µm; for AM powders, narrowly defined fractions are also common.

In this step, the metallic tungsten powder is produced from the oxide precursor. This significantly influences the purity and powder characteristics.

The core process requires furnace technology; depending on the application, this is followed by deagglomeration, classification and representative sample division.

Homogenization and sample division ensure reliable test values for PSD, density, flow behavior and release criteria.

Key factors include target particle size, particle size distribution, morphology, apparent density, Hall flow, and oxygen content.

Ing. Klaus Ebenauer