An investigation of static, dynamic, and extreme dynamic strain rate properties in binder jetting tungsten heavy alloys

This study investigates the mechanical properties and failure mechanisms of tungsten heavy alloys (WHAs) fabricated via binder jetting (BJT)—an indirect additive manufacturing technique—versus conventional liquid-phase sintering (LPS) across wide strain-rate regimes. A 93W-5Ni-2Fe alloy printed by BJT with subsequent heat treatment exhibits a microstructure of W particles within a Ni-Fe binder phase. BJT-processed WHAs demonstrate approximately doubled W particle size and marginally higher W-W contiguity (C_W-W≈0.307) than LPS counterparts (C_W-W≈0.291). Quasi-static tensile tests reveal 17.3 % and 4.8 % higher yield and tensile strength for BJT WHAs relative to LPS, yet reduced elongation (24.5 % vs. 39.0 %). The dominant fracture mode transitions from ductile (LPS) to mixed brittle-ductile in BJT, characterized by tungsten cleavage (“river patterns”) and binder-phase dimples. Dynamic compression (1000–5000 s⁻¹) indicates lower compressive strength and strain-rate sensitivity in BJT WHAs. Ballistic evaluations confirm comparable penetration performance (within 3 %) between BJT and LPS long-rod penetrators under extreme conditions. Residual penetrator analysis identifies penetration failure mechanisms: mushroom-head segmentation via structural-design-induced macrocracks and adiabatic shear band (ASB)-derived microcracks. This work establishes a foundation for BJT WHAs in the field of impact dynamics.