U.S. Patent No. 12,359,290 Tungsten Heavy Metal Alloy Powders and Methods of Forming Them
Elmet Technologies, the last and only fully integrated, U.S.-owned and operated tungsten and molybdenum manufacturer, today announces the issuance of U.S. Patent No. 12,359,290 titled “Tungsten Heavy Metal Alloy Powders and Methods of Forming Them.”
As the fifth U.S. patent granted in this field, it recognizes Elmet Technologies’ continued innovation in powders for additive manufacturing and powder metallurgy applications.
The patented 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 & 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).
- Superior Densification: Plasma-treated particles reach up to 65% of theoretical density, minimizing shrinkage and defects during sintering.
In addition, the technology 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.
This patent builds on a lineage of foundational IP developed by Elmet Technologies, reinforcing its position as a global leader in refractory metal solutions.
About Elmet Technologies
Elmet Technologies is the only U.S.-owned and operated, fully integrated tungsten and molybdenum manufacturer. Its corporate headquarters is in Lewiston, Maine, USA. With its 2023 acquisition of H.C. Starck Solutions Americas, Elmet is now the largest U.S.-owned producer of tungsten and molybdenum materials and products, with nearly 400 employees across three world-class facilities, totaling over 500,000 square feet in Maine, Ohio, and Michigan, USA.
Since 1929, Elmet Technologies has been proudly servicing its customers and applications, including defense, aerospace, medical, semiconductor, industrial furnace, and more. Elmet Technologies’ three world-class manufacturing facilities each fabricate materials to its global customers’ most exacting specifications. Elmet is ISO9001, AS9100, and ITAR registered.
