Study of the Structure and Properties of a W–Cu Composite Produced by an Extrusion-Based Additive Technology

Synthesis, printing, and sintering processes of W–Cu composite materials produced by additive manufacturing were investigated in an integrated manner. A W–Cu powder obtained by electrical explosion of wire, providing high purity and particle uniformity, was used as the starting material. To prepare the feedstock, the powder was mixed with a polymer binder, and extrusion parameters, including temperature, feed rate, and pressure, were optimized to minimize porosity in printed samples. Particular attention was given to the rheological properties of the feedstock, which strongly influence print quality. Debinding and sintering were carried out in a reducing Ar–H2 atmosphere to prevent oxidation of the components. Sintering at 1050–1100°C results in high material density with a uniform distribution of tungsten particles in the copper matrix. Mechanical testing shows that the microhardness of the samples is 144 ± 16 HV and the flexural strength reaches 320 ± 12 MPa. Anisotropy of tribological properties is observed due to the orientation of layers during printing, which must be taken into account in design. The results demonstrate the potential of additive manufacturing for producing W–Cu composites with tailored properties, opening prospects for applications in electronics, aerospace, and other high-technology fields. Further work may focus on optimization of feedstock composition and investigation of the effect of post-processing on functional properties.