Powder metallurgy is a key method for preparing molybdenum foil, transforming molybdenum powder into high-performance thin sheets through multiple steps. Initially, high-purity molybdenum powder (≥99.95% purity) with a particle size of 1-10 μm is selected to ensure low impurities (e.g., carbon, oxygen). The powder is compacted in a mold under high pressure (100-300 MPa) to form billets, customizable in shape. Next, the billets are sintered at 1800-2200°C in a vacuum or hydrogen atmosphere, bonding particles and densifying the structure to 90-95% of the theoretical density (10.28 g/cm³). Post-sintering, billets may retain micropores, requiring hot forging or hot rolling to further densify, achieving near-theoretical density. The billets are then hot-rolled (1200-1600°C) into thinner sheets, followed by cold rolling for precise thickness (0.1-1 mm). Finally, annealing (800-1200°C) relieves internal stress, enhancing ductility (elongation 8-15%). Surface treatments (e.g., acid washing, polishing) remove oxides, improving smoothness. The process excels in producing complex shapes and large or custom foils but may leave micropores, reducing strength, and is costly. Quality control involves powder purity analysis (spectroscopy), sintered density testing, and microstructure inspection. The foil’s tensile strength is 450-600 MPa, hardness 140-180 HV, suitable for electronics, aerospace, and high-temperature furnaces.
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