The primary disadvantage of using tungsten is its poor ductility and brittleness at low temperatures, which makes it difficult to machine and fabricate. This issue is particularly pronounced because tungsten's ductile-to-brittle transition temperature is usually higher than room temperature.
Explanation:
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Difficulty in Machining: Pure tungsten is notoriously hard to machine due to its extreme hardness and high melting point. Traditional diamond tools used for machining other hard materials like tungsten carbide are ineffective with pure tungsten because the material can compact into the spaces between the diamonds, a condition known as "loading." This renders the cutting tool unable to cut effectively. Additionally, pure tungsten cannot be drawn over a mandrel or extruded into a tube, further complicating its fabrication processes.
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Brittleness at Low Temperatures: Tungsten exhibits poor ductility and becomes very brittle at temperatures below its ductile-to-brittle transition temperature. This characteristic makes it challenging to work with in typical industrial environments where temperatures are not significantly elevated. The brittleness can lead to material failure during forming or machining processes, necessitating careful control of temperature and fabrication techniques.
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Sensitivity to Impurities: Tungsten can also become brittle and difficult to work with when it is impure or contaminated with other materials. This sensitivity to impurities requires careful handling and processing to maintain its structural integrity. Moreover, tungsten oxidizes in air at elevated temperatures, which necessitates a protective gas atmosphere or reducing atmosphere during welding to prevent material degradation.
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Complex Fabrication Processes: The production of tungsten products, especially thin wires and large rods, involves a complex, multistep process that includes pressing, sintering, swaging, and repeated drawing and annealing. These processes are not only time-consuming but also require precise control of temperature and pressure, adding to the overall cost and complexity of manufacturing tungsten components.
In summary, while tungsten possesses many desirable properties such as high melting point, resistance to oxidation, and extreme hardness, its poor ductility and brittleness at low temperatures, coupled with the complexity of its fabrication processes, present significant challenges in its use and application. These factors must be carefully managed to leverage the benefits of tungsten effectively.
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