Engineering Resource
Tungsten heavy alloys exist for density. That single property brings with it a machining behaviour closer to a tough, abrasive metal than to anything easy — and the process has to respect it.
What tungsten heavy alloys are
Tungsten heavy alloys are tungsten-based composites with nickel-iron or nickel-copper binders, typically around 90–97% tungsten by weight and 17–18.5 g/cm³ in density — roughly twice that of steel. Pure tungsten is extremely brittle; the binder is what makes the material machinable at all.
Why they are difficult
- Abrasive: the tungsten phase wears tools quickly.
- Tough: the binder resists cutting and can smear.
- Dense: mass affects fixturing and vibration behaviour.
- Heat: poor conduction keeps heat at the cutting edge.
Process controls that work
Dedicated tooling with wear-resistant geometry, moderate cutting speeds and a rigid setup that respects the part's mass; constant feed to avoid rubbing and work hardening; and controlled deburring, because tungsten alloy edges chip rather than deform. Critical dimensions are verified on a Zeiss CMM for geometry and position, the TRIMOS V5 height gauge for heights and steps, and the AI-Vision system for fine features.
Where they are used
Counterweights and ballast, radiation shielding, vibration damping masses, and precision masses in aerospace, medical and instrumentation equipment.