MANUFACTURING PROCESS

Raw tungsten powder is mixed on-site with lower melting point metal powders – typically nickel, copper, or iron – to achieve the desired alloy grade, determined by the required density, application, and relevant industry standards.

All raw materials have full certification, tungsten powders are fully traceable, and all mixed powders are tested to adhere to the relevant specifications and grade ingredients.

The tungsten powder mixture is pressed into a solid block using either isostatic presses running at approximately 25,000 psi or hydraulic presses, binding the powder particles and establishing the near-net shape of the finished component.

Various well-defined near net shapes and sizes are produced at this stage, in line with the finished item requirements.

Basic machining known as forming, or green machining, is carried out to cut the compacted powder into pre-sintered shapes.

This reduces the volume of material to be removed after sintering, minimising material usage, cost, and machining time. All machined-off powder is recycled in-house, supporting both process efficiency and environmental responsibility.

Formed parts are sintered using Wolfmet’s on-site batch (static), or pusher (continuous) furnaces running at circa 1480°C, which converts the pressed powder into the solid composite tungsten metal alloy.

Parts shrink by approximately 15% during sintering, but no mass is lost – which increases the density of the material to the required specification. All batches are density-checked using the Archimedes principle as part of standard quality control.

The sintered alloy is machined into the final parts using various CNC machining centres, millers and lathes:

In addition, Wolfmet offers precision grinding, wire erosion, and electrical discharge machining (EDM) on request.

Prior to dispatch, all tungsten alloy parts are inspected for dimensional tolerances, traceability and density: