Elmet Technologies granted US patent for tungsten AM powders
The process leverages advanced spray drying and optional plasma densification techniques to produce substantially spherical, flowable, and highly densified composite particles
Elmet Technologies, a fully integrated, US-owned and operated tungsten and molybdenum manufacturer, has been granted a US patent (no. 12,359,290) for “Tungsten Heavy Metal Alloy Powders and Methods of Forming Them.” As the fifth US patent granted in this field, it recognizes Elmet Technologies’ continued innovation in powders for additive manufacturing and powder metallurgy applications.
The process leverages advanced spray drying and optional plasma densification techniques to produce substantially spherical, flowable, and highly densified composite particles. This unique material structure improves powder bed uniformity and thermal conductivity during sintering – key advantages for fabricating aerospace, defense, and industrial parts where mechanical strength and precision are critical.
“This patent reinforces Elmet Technologies’ commitment to materials innovation,” said Michael T. Stawovy, Co-inventor and Director of Research and Development at Elmet Technologies. “Our approach enhances the production of tungsten heavy alloy powders with exceptional flowability and chemical uniformity – features essential to achieving repeatable, high-quality parts through additive manufacturing.”
Key features of the patented invention include: Tailored Alloy Compositions (including 90% tungsten with carefully controlled additions of nickel, iron, copper, cobalt, or manganese); Improved Powder Morphology (substantially spherical particles with reduced porosity and enhanced flow rate – as low as 7 seconds/50g by Hall flow method); and Superior Densification (plasma-treated particles reach up to 65% of theoretical density, minimizing shrinkage and defects during sintering).
The technology also addresses a long-standing challenge in metal additive manufacturing – producing highly pure, flowable powders that retain their shape and properties under extreme processing conditions. The resulting powders are well-suited for binder-jet printing and other powder-bed techniques, enabling the production of high-strength tungsten parts for extreme environments.
