Powders for 3D Printing

ADVANTAGES

APPLICATION

Biomedical Components, Propulsion, Heat Management

MARKET SEGMENT

Industrial Processing, Aerospace & Defense, Electronics, Medical

MATERIALS

Mo, W, WHA, C103, pure Ta, NRC76, Ta10W, Ta3W, TZM, MoLa, WRe

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Spray Drying

Spray Drying

Spray drying is a critical process in the generation of high-performance thermal spray powders for various end-use applications. It is key in ensuring the homogeneity and uniformity of metal powders intended for deposition onto a wide range of substrates in a semi-molten state. Each of these properties is a vital metric in the eventual functionality of deposited coatings. The performance of automotive components, heat management systems, and numerous other products can stem back to this preparatory stage of raw material processing.

H.C. Starck Solutions has succeeded in synthesizing the highest quality refractory powders from a broad range of technology metals, including molybdenum (Mo) and tungsten (W). These advanced thermal sprays serve the purpose of fixing non-uniform surfaces and protecting against the destructive effects of erosion and general wear-and-tear.

The success of H.C. Starck Solutions thermal spray powders depends on the quality of the underlying raw material, which can be compromised by spray drying. H.C. Starck Solutions spray drying capabilities support the generation of highly-engineered products with tight control of particle morphology, size distribution, and mechanical strength. The result: Thermal sprays with outstanding sphericity and flowability, ensuring even coatings of myriad substrate materials, even for contiguous layers.

Spray-Drying Services from H.C. Starck Solutions

H.C. Starck Solutions has expanded this unique capability, offering customers the benefit of their expertise in the processing of advanced thermal spray powders at the earliest stage. Numerous refractory powders can be dried with tight control of particle properties by adjusting the drying parameters and feedstock characteristics.

With almost 100 years’ experience in powder metallurgy and a worldwide network of research and development (R&D) laboratories and manufacturing facilities, H.C. Starck Solutions occupies the cutting-edge of powder processing for demanding areas of application. Combustion engine components and high-density high-power electronics are merely two examples of the various components that H.C. Starck Solutions spray-drying capabilities can optimize and revolutionize.

If you would like more information about the materials available for H.C. Starck Solutions powder spray-drying services, please do not hesitate to contact a member of the team today.

SUPPORT OR ANY QUESTIONS?

Please reach out with specific requests of materials that are not listed and a member of our team will get back to you.

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Plating

PLATING

Material processing for challenging applications often requires a novel solution. H.C. Starck Solutions highly qualified process engineers and developers have long been collaborating with customers to meet unique industry requirements with value-added resolutions. This has culminated in one of the core services on offer from H.C. Starck Solutions. Using high-purity molybdenum (Mo) as a base material, H.C. Starck Solutions routinely generates composite plates using a choice of electrodeposited metals, including:

  • Precious metals like gold (Au) and silver (Ag).
  • Transition metals like nickel (Ni), rhodium (Rh, and ruthenium (Ru).

H.C. Starck Solutions plating service exploits the exceptional thermodynamic properties of molybdenum, including its high strength and stiffness under refractory conditions. It is one of the highest performing substrate materials for plating in aerospace and defense, electronics, and industrial processing applications, benefitting from exceptional adherence with deposited metal coatings. H.C. Starck Solutions molybdenum plates can withstand extremely high temperatures without softening or expanding, enabling the functional coating to retain its desired characteristics throughout operating conditions.

The challenge of electroplating on molybdenum substrates is the material’s relatively high reactivity with other metals. This can result in the generation of undesirable oxides that inhibit adhesion between the substrate and the coating material. H.C. Starck Solutions has a wealth of experience in design and engineering with challenging refractories, including molybdenum and its alloys. These problems can subsequently be overcome with confidence, ensuring uniform functional coatings of high-performance molybdenum substrates for sectors as challenging as semiconductor and chemical processing.

If you would like any more information about H.C. Starck Solutions electroplated coatings and electroless nickel coating services, please contact a member of the team today.

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Electron Beam Melting

ADVANTAGES

A number one priority for H.C. Starck Solutions is our contribution to the environment. To advance our sustainability development, we offer customers the unique service of recycling spent or used products through our electron beam melting (EBM) furnace.

Electron beam melting technology at H.C. Starck Solutions uses recycled molybdenum, tantalum and niobium as part of its raw material input. The process employs electrons to bombard the material in the EBM furnace, so the material melts and falls into a water-cooled copper mold where it solidifies into a round ingot. The ingot is then forged and formed into the desired shape.

Electron beam melting is carried out under high vacuum in the EBM furnace. In the instance of molybdenum, the elements with melting points lower than molybdenum volatilize which leaves the molybdenum more than 99.95 % pure and 100 % dense.

H.C. Starck Solutions continues to improve its electron beam melting processes to offer customers the most efficient and cost saving alternatives.

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3D Screen Printing

ADVANTAGES

Fast and efficient AM Method especially for small parts at high volumes.

  • A UV-curable emulsion is used to create a pattern (mask) for ink/paste on a woven steel screen.
  • Printing is done layer by layer pushing paste through the screen.
  • Drying after each layer is necessary to provide a stable base for the next layer.
  • A sintering step is done to achieve final properties.

Main Characteristics:

  • High resolution (<100µm)
  • Excellent wall thickness control
  • Suited for standardized powders
  • Large build areas
  • Economical solution

APPLICATION

Chemical Processing Equipment, Radiation Management

MARKET SEGMENT

Industrial Processing, Aerospace & Defense, Electronics, Medical

MATERIALS

WHA

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Balls / Spheres

ADVANTAGES

APPLICATION

Munition/

MARKET SEGMENT

Industrial Processing, Aerospace & Defense, Electronics

MATERIALS

W, WHA, WCu

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High Performance Powders

ADVANTAGES

As a world leader in the development and manufacture of high-performance metal powders, H.C. Starck Solutions offers one of the most comprehensive and robust product portfolios ever assembled. With a mastery of metallurgic processing and unsurpassed technical expertise, H.C. Starck Solutions can reliably meet and exceed customer expectations and market requirements with a suite of tailor-made, high-performance powders suitable for a wide range of market sectors.

APPLICATION

MARKET SEGMENT

Electronics

MATERIALS

Mo, TZM, ZrC, pure Ta, W, WHA

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Each quotation will be unique to the customer requirements so please give as much information in the contact form as possible, this will enable us to get the most accurate price back to you.


H.C. Starck Solutions is synonymous with exceptional quality powder materials based on advanced metals and their alloys. These include, but are not limited to:

  • Pure molybdenum (Mo) and titanium-zirconium-molybdenum (TZM).
  • Pure tantalum (Ta).
  • Pure tungsten (W) and tungsten heavy alloy (WHA).
  • Zirconium carbide (ZrC).

Quality-Assured High-Performance Powders

H.C. Starck Solutions quality-assured materials development and processing capabilities ensure that high-performance powders can be generated to specific customer requirements with exceptional material properties. This includes: uniform, spherical powder morphology with tight control of particle size distributions (PSDs); exceptional flowability; high reproducibility; and outstanding purity levels.

Tungsten metal powders are produced by reducing tungsten oxides (WOx) in a controlled hydrogen atmosphere. Tight control of process temperature, humidity, and additional dopants enables H.C. Starck to finely tune the coarseness of tungsten high-performance powders before additional carburization processes occur. This enables a diverse range of powder grades with average Fisher grain sizes across an approximate range of 0.7—50 micrometers (µm). H.C. Starck Solutions molybdenum powders are similarly produced in a hydrogen atmosphere, using molybdenum trioxide (MoO3) and ammonium molybdates. This is a finely-tuned process that enables the generation of high-performance molybdenum powders with a mean particle size of 20—30 µm.

World-class application technology and laboratory services enable H.C. Starck Solutions to tightly control the processing parameters for a range of refractory metals. This forms the backbone of H.C. Starck Solutions customer-specific powder design capabilities. If you would like to learn more, simply contact a member of the team today.

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Powders for AM

ADVANTAGES

Spherical powder morphology, Exceptional flowability, Excellent reproducibility, High purity levels.

H.C. Starck’s AM powder and wire feedstock offers world class quality and performance with perfectly tailored properties suited for all relevant AM methods.

APPLICATION

AM, Thermal management

MARKET SEGMENT

MATERIALS

Mo, W, Specific alloys?, C103, pure Ta, NRC76, Ta10W, Spherical

REQUEST A QUOTE

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Each quotation will be unique to the customer requirements so please give as much information in the contact form as possible, this will enable us to get the most accurate price back to you.


 

Materials

Our Feedstock Solutions

H.C. Starck Solutions innovative powder and wire manufacturing technology coupled with our vertically integrated supply chain and metallurgical expertise ensures the highest quality materials for demanding applications and environments. Our advanced technological processes enable us to customize our refractory metal feedstock to precise requirements

achieving outstanding material properties and optimum performance for additive manufacturing.

Our Powder Advantage

H.C. Starck Solutions powders are specifically designed to meet the demanding requirements of additive manufacturing technologies. Their properties exceed traditional production

specifications and offer:

  • High purity
  • High bulk density
  • Spherical powder morphology
  • Exceptional flowability
  • Low oxygen
  • PSD optimized for specific printing methods

Also include content from the Brochure “Refractory Metal Powders for Additive Manufacturing”

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Tubes

ADVANTAGES

H.C. Starck Solutions offers TA tubing and molybdenum tubes for producing quartz tubing and for quartz melting. Using its extrusion experience, H.C. Starck Solutions fabricates large diameter molybdenum tubing ideal for quartz melting vessels, mandrels and orifice plates.

H.C. Starck Solutions has vast experience in the manufacturing and processing of high performance materials, including molybdenum and their alloys. These advanced materials play a key role in the glass industry’s challenging applications in feeding, melting, homogenizing, and shaping of glass products.

APPLICATION

Chemical Processing Equipment

MARKET SEGMENT

Industrial Processing, Aerospace & Defense, Electronics

MATERIALS

Mo, Mo EBM, Mo30W, TZM, MoLa, Nb, Grain stabil. Nb, Nb EBM, Ta, Ta EBM, NRC, Ultra 76, Ultra 76 Plus, W

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Sheet / Plate / Foil

ADVANTAGES

H.C. Starck Solutions tantalum sheet and foil are popular for chemical processing applications, where customers can convert it into lining for columns, vessels, tanks, reactors, parts for heat exchangers, and more.

APPLICATION

High Temperature Processing

MARKET SEGMENT

Industrial Processing, Aerospace & Defense, Electronics

MATERIALS

Mo, Mo EBM, CuMoCu, MoCu, NiMoNi, TZM, MP35N, MoLa, Nb, Stabil. Nb, Nb EBM, Ta, Ta EBM, TaW, W, (W, Ni, Fe), NRC76, Ultra 76, Ultra 76 Plus, Ta10W

REQUEST A QUOTE

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TANTALUM SHEET, PLATE, ROUND DISK AND FOIL

Customers transform our tantalum plate into products for military, chemical processing, and other anti-corrosion type applications.

Both tantalum sheet and plate are used by customers in the manufacturer of components for anticorrosion equipment. Round discs cut from tantalum plate are employed to repair and reinforcement work in anti-corrosion equipment.

Because of their strength and workability, very thin sheets of tantalum can be clad to other surfaces, providing superior corrosion protection and cost effectiveness.

Our tantalum sheet and plate are supplied with a cold-rolled and chemically cleaned surface. The sheet and plate may be locally conditioned to remove defects, provided that thickness tolerance is maintained.

Depending on your specifications and needs, all of our tantalum sheet, plate, and foil are visually inspected for slivers, laminations, excessive roll marks and handling scratches.

ULTRA76 Ta alloys offer higher corrosion resistance in most environments generating value added by extending product life time, reducing material thickness and improving processes throughput.

  • Higher temperatures possible, shorter cooling/heating cycle times
  • Constant surface finish (Ra<0.8 micrometers)
  • Material only from non-conflict sources, H.C. Starck Solutions is EICC certified
  • Uniform wall thickness
  • Best flatness for explosion clad applications

Dimensions

Form Thickness, Dia., Wall
inches (mm)
Width, Length
inches (mm)
Tantalum Foil 0.001“ to 0.005“
(0.025 to 0.1270 mm)
12“ maximum width x coil
(30.5 mm max. width x coil)
Tantalum Sheet 0.005“ to 0.020“
(0.1270 to 0.50 mm)
36“ maximum width x coil
(915 mm max. width x coil)
Tantalum Sheet 0.015“ to 0.060“
(0.380 to 1.524 mm)
40“ width x coil
(1000 mm width x coil)
Tantalum Round Disk Thickness: 0.060″ to 0.125″
(1.524 to 3.175 mm)
Up to 37 in diameter
Tantalum Plate 0.060“ to 0.125“
(1.524 to 3.175 mm)
width not to exceed 40“
(1000 mm)

*Total weight of finished plate not to exceed 350 Ib.

Mechanical Properties for Sheet and Plate

Grade and Form Ultimate Tensile Strength
min, psi (MPa)
Yield Strength
min, psi (MPa) (2% Offset)
Elongation
min, % (1 inch GL)
Unalloyed Tantalum (R05200), (R05400) Plate, Sheet and Strip
0.003“ – 0.060“ thick
>_ 0.060“ thick
30 000 (207)
25 000 (172)
20 000 (138)
15 000 (103)
20
30
97.5% Tantalum, 2.5% Tungsten,
(R05252) Sheet and Strip
Plate
40 000 (276)
40 000 (276)
30 000 (207)
28 000 (193)
20
20

Please contact us for additional sizes and requirements.

Tantalum and Tantalum Alloy Products:

Refer to Product Data Sheets for Tantalum for sizes:

PD-7033 NRC Ultra 76 Tantalum Alloy (Ta 2.5%W)
PD-7035 NRC Tantalum (UNS R05200)
PD-7036 NRC Tantalum Beam Melted Tantalum (ETA) (UNS R05200)

TUNGSTEN PLATE, SHEET, AND FOIL

Tungsten mill products available from H.C. Starck Solutions include plate, sheet, and foil with many options on width, length and thickness. Pure Tungsten flat rolled products are fabricated from pressed and sintered powder metallurgy ingot and are rolled to a wide range of plate, sheet, and foil thicknesses.

Flat rolled products

Pure Tungsten flat rolled products are fabricated from pressed and sintered powder metallurgy ingot and are rolled to a wide range of plate, sheet, and foil thicknesses.

The material is 99.95% pure Tungsten sheet and is normally supplied as-rolled in thicknesses below 0.030″, and stress relieved at that thickness and above.

Thickness Tolerance
Thickness Tolerance Width Tolerance Length Tolerance Flatness Tolerance
Thickness (Inches) (% of Thickness) (Inches) (Inches) (% Maximum)
.1875 to .625 ± 4  +.125 -0  +.125 -0 5
Over .500 to 1.125 ± 5  +.125 -0  +.125 -0 5

Plate camber (edge straightness) = Maximum .0625 inch per foot of length.

Plate will be sheared, abrasive cut, band saw cut, or water jet cut to the tolerances shown.

Surface Condition

Tungsten plate is normally supplied with a uniform matte finish, clean and free from foreign matter. Major surface defects will be removed by grinding provided that such conditioning does not reduce dimensions below specified limits.

PURE TUNGSTEN SHEET 4202

Physical Characteristics:

Thickness Tolerance
Thickness (Inches) Up to 12 Inches wide (Inches) Over 12 thru 24 Inches wide (Inches)
0.005 to 0.008 ± 0.0007
Over 0.008 to 0.011 ± 0.001
Over 0.011 to 0.015 ± 0.0012
Over 0.015 to 0.020 ± 0.0015
Over 0.020 to 0.040 ± 0.002
Over 0.040 to 0.187 ± 5 % ± 5 %

*For thickness 0.040 to 0.187 inches; sheet will be sheared, abrasive cut, band saw cut, or water jet cut to the tolerances shown.

Bedsheet is sold as a useable width, therefore any cracks or delaminations on the edges are acceptable as long as a 6, 12 or 24 inch minimum width can be yielded from the material.

Length Tolerance

For specified lengths, the tolerance for all sizes is + .0625 – 0 inch per foot of length. Edge Straightness-Maximum camber is .0625 inch per foot of length.

Flatness Tolerance

The total deviation from flatness will not exceed 4 % maximum.

PURE TUNGSTEN FOIL 4201

Physical Characteristics

Thickness Tolerance
Thickness Available Width (Inches) Tolerance (Inches)
0.002 ± 0.0003 250 to 6
0.003 ± 0.0004 250 to 12
0.004 ± 0.0005 250 to 12
0.0049 ± 0.0007 250 to 12

Tolerance for intermediate thickness will correspond to next heavier thickness shown.

Width Tolerance
SLIT WIDTH SHEARED WIDTH (INCHES) (INCHES)
Thickness (Inches) over .500 thru 6 wide Inches over 6 thru 12 wide Inches over .500 thru 12 wide Inches
0.002 to 0.049 ± .010 ± .015 ± .031

Tungsten discs, washers and squares for power semiconductors

Tungsten is widely used as contact materials in silicon controlled rectifiers diodes, transistors and thyristors (GTO’S). Other than in specialist applications, molybdenum is now accepted as the first choice mounting material for power semiconductor devices due to its significantly lower cost and weight.

The fact that both materials have a similar coefficient of expansion to silicon combined with high thermal conductivity makes them an ideal choice, especially in large area power devices where considerable heat is generated. Further applications include the use of molybdenum and tungsten as heat sink bases in IC’S, LSI’S and hybrid circuits.

TUNGSTEN DISCS
PRODUCTION METHOD THICKNESS DIAMETER
mm inch mm inch
PUNCH 0.1 – 0.3 0.004 – 0.012 5.0 – 30.0 0.200 – 1.20
0.31 – 0.5 0.012 – 0.020 10.0 – 40.0 0.400 – 1.60
0.51 – 1.0 0.020 – 0.040 10.0 – 50.0 0.400 – 2.00
1.1 – 2.0 0.040 – 0.080 20.0 – 50.0 0.800 – 2.00
2.1 – 3.0 0.080 – 0.160 20.0 – 60.0 0.800 – 2.50

 

TUNGSTEN SQUARES
PRODUCTION METHOD THICKNESS DIAMETER
mm inch mm inch
SAW 0.010 – 0.50 0.004 – 0.020 0.50 – 10.0 0.020 – 0.40
0.51 – 1.00 0.020 – 0.040 1.00 – 70.0 0.040 – 2.80
1.10 – 2.00 0.040 – 0.080 5.00 – 75.0 0.200 – 3.00
PUNCH 0.20 – 0.50 0.008 – 0.020 5.00 – 25.0 0.200 – 1.00
0.51 – 1.00 0.020 – 0.040 15.0 – 55.0 0.600 – 2.00
1.10 – 2.00 0.040 – 0.080 10.0 – 75.0 0.400 – 3.00
EDM 0.50 – 1.00 0.020 – 0.040 10.0 – 100.0 0.400 – 4.00
1.10 – 2.00 0.040 – 0.080 10.0 – 200.0 0.400 – 0.80
2.10 – 6.00 0.080 – 0.240 20.0 – 200.0 0.800 – 8.00

Length Tolerance

For specific lengths, tolerance is + .0625 – 0 inch per foot of length. Tungsten foil is supplied in a coil having a minimum internal diameter of 3 inches, with a minimum coil length of 10 feet.

Surface Condition

Foil will have a bright finish and will be essentially free of surface defects or edge delaminations as determined by visual examination. Special mirror finish material is available upon request.

MOLYBDENUM PLATE, SHEET AND FOIL

Vacuum Arc-Cast Molybdenum Mill Products

The VAC method of consolidation is unique to H.C. Starck Solutions. Materials made by this process is available exclusively from H.C. Starck Solutions and yields a homogeneous product which is very low in residual elements, provides better strength at elevated temperatures and exhibits excellent workability, weld-ability and good machining characteristics.

In the vacuum arc-casting process, 99.95% pure molybdenum powder, ultra-pure molybdenum powder or one of our molybdenum-base alloys is pressed, sintered, and melted (all under vacuum) to produce a casting weighing up to one ton. This arc-casting is then further worked by extrusion followed by forging or rolling.

Where highest purity, maximum toughness, and ductility at low temperatures are required, arc-cast molybdenum mill products are available in a special low-carbon grade. This material is 99.97% pure molybdenum and contains a maximum of .010% residual carbon, compared to the nominal .030% maximum carbon content of normal arc-cast molybdenum.

Workability and machinability are also superior with this special product.

H.C. Starck Solutions produces a wide range of molybdenum and molybdenum alloy mill products using two primary consolidation methods; vacuum arc-casting (AC) and powder metallurgy (PM). The availability of products from both of these established processes gives users many options in selecting a material to satisfy their specific application requirements. Mill products available from either process include forging billets, bar, rod, sheet, plate and foil.

Refer to Product Data Sheets for further Molybdenum sizes:

Molybdenum Forms and Tolerances
Form Thickness Width Length
Sheet 0.005” to 0.187” 24” max. sheet **
(0.127 to 4.750 mm) (610 mm) (2.438 m) or coil*
Foil 0.001” to 0.0049” 1/2” to 12” coil
(0.0254 to 0.12 mm) ( 12.7 to 305 mm)

Molybdenum Pure Products

PD-7000 Pure Molybdenum AC Bar Low Carbon
PD-7006 Pure Molybdenum AC Bar
PD-7009 Pure Molybdenum PB PM Bar
PD-7010 Pure Molybdenum PSB PM Billet
PD-7029 Pure Molybdenum Plate PP-22-2
PD-7014 Pure Molybdenum Sheet Premium Grade PS-100-2
PD-7016 Pure Molybdenum Sheet Standard Grade PS-300-2
PD-7017 Pure Molybdenum Foil F-21-5
PD-7026 Pure Molybdenum ABL AC Bar Low Carbon
PD-7028 Pure Molybdenum ASL AC Sheet 3202 Low Carbon
PD-7030 Pure Molybdenum APL AC Plate 3203 Low Carbon

Molybdenum Alloys Products

PD-7001 Molybdenum Alloy TZM PM Sheet 2702
PD-7011 Molybdenum Alloy TZM PM Plate 2703
PD-7004 Molybdenum Alloy TZM AC Plate 3403
PD-7005 Molybdenum Alloy TZM AC Sheet 3402
PD-7021 Molybdenum Alloy TZM AFBT AC Forging Billet
PD-7025 Molybdenum Alloy TZM ABT AC Bar
PD-7031 Molybdenum Alloy P/M TZM PM Billet
PD-7043 Molybdenum Alloy ODS Mo-La PM Sheet 2602
PD-7044 Molybdenum Alloy ODS Mo-La PM Plate 2603
PD-7020 Molybdenum Alloy AFB-30W AC Forging Billet
PD-7022 Molybdenum Alloy AFB AC Forging Billet
PD-7024 Molybdenum Alloy AB-30W AC Bar
PD-7008 Molybdenum Alloy PBT PM Bar

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