Sustainable processing of tungsten heavy alloys via ultrasonic recycling and aluminum addition: microstructure and mechanical property optimization

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Abstract This study presents the sustainable preparation and characterization of a novel Class 2 tungsten heavy alloy (WHA) reinforced with varying aluminum (Al) contents (0–4 wt%). High-purity recycled tungsten powder was produced via ultrasonic-assisted acidic leaching and alloyed with nickel (Ni) and iron (Fe) using the powder metallurgy technique. X-ray diffraction (XRD) and scanning electron microscopy (SEM) analyses confirmed phase evolution and significant microstructural refinement. The average tungsten grain size decreased from 17.9 μm (0% Al) to 9.8 μm (4% Al). Density measurements showed that porosity decreased notably at 3% Al content. The 2% Al alloy achieved the highest compressive strength of 2310.8 MPa and excellent ductility, while the 4% Al alloy exhibited superior hardness (36.1% increase) and wear resistance (49.5% improvement). True stress–strain analysis revealed enhanced elastic limits and work-hardening behavior at intermediate Al additions. Moreover, bearing zone percentages, determined via Abbott–Firestone analysis, showed a consistent increase with higher Al contents, indicating improved load-bearing surface characteristics. These findings demonstrate that controlled aluminum alloying significantly enhances densification, microstructure uniformity, and mechanical performance, positioning recycled WHAs as promising candidates for high-stress industrial applications.

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