Tungsten-rhenium alloys are difficult to process by traditional manufacturing given that refractory metals and alloys have some of the highest melting point of all elements. While refractory metals can be hot worked, traditional processing methods of tungsten require temperatures on the order of 2800 to 3000°F using a die made of very high temperature capable tool which can be quite expensive. These very high process temperatures also limit tool life, require protective atmospheres to prevent severe oxidation, and result in relatively poor microstructure-properties. Existing production methods to make mill and wire products also have considerable material waste, long lead times, and of course low yields. Because of these and other issues, this SBIR Phase I effort will demonstrate a novel approach to more cost-effectively producing W-Re alloy wires from existing material stockpiled by the DLA. This new process will be shown to be not only lower cost, but also safer Reductions in final product cost will also be possible given that less starting material will be needed and a much higher yield rate should be possible. The proposed technology will even allow for better microstructural control and therefore more robust W-Re wire properties.
