Tungsten is not commonly used as a heating element primarily due to its susceptibility to oxidation and embrittlement at elevated temperatures, and its challenging fabrication properties. While tungsten has a high melting point and excellent thermal stability, making it suitable for high-temperature applications, its tendency to oxidize rapidly in air above 500°C and its brittleness at low temperatures limit its practical use as a heating element in many industrial settings.
Oxidation and Embrittlement: Tungsten oxidizes in air starting around 500°C and this process accelerates above 1200°C. This rapid oxidation not only degrades the material but also compromises its structural integrity, making it unsuitable for use in open air environments where heating elements are typically exposed to oxygen. Additionally, tungsten is prone to embrittlement, which can lead to mechanical failure under thermal and mechanical stresses. This susceptibility requires careful temperature control and protective atmospheres, which complicates its use and increases operational costs.
Fabrication Challenges: Pure tungsten is notoriously difficult to machine and fabricate due to its high ductile-to-brittle transition temperature. This means that below a certain temperature, tungsten becomes brittle and prone to cracking or shattering, which complicates the manufacturing process. The material's brittleness at low temperatures also makes it challenging to work with, requiring specialized techniques and equipment. Furthermore, tungsten cannot be easily drawn or extruded into tubes, which are common forms for heating elements, without specialized and costly processes.
Operational Considerations: The use of tungsten heating elements requires a controlled environment, typically under vacuum or in a protective gas atmosphere, to prevent oxidation and maintain material integrity. This requirement adds significant complexity and cost to the operation of furnaces and other heating systems, making it less practical compared to materials that can withstand oxidation and do not require such stringent environmental controls.
Despite these challenges, tungsten is used in specialized applications where its unique properties, such as high melting point and low vapor pressure, are indispensable. For instance, in vacuum electron devices and metal injection molding furnaces, tungsten's properties are crucial for achieving the necessary performance. However, for general heating applications, the drawbacks of tungsten outweigh its benefits, leading to the preference for other materials like nichrome or molybdenum disilicide, which offer better resistance to oxidation and are easier to work with.
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