Replacing toxic lead in marine applications with brass-40 wt.% tungsten composites

Abstract Environmental and health concerns about lead-based materials have increased the need for high-density, lead-free alternatives for fishing weights, hunting bullets, ammunition, and body armor applications. Brass/40 wt.% W composites were manufactured by powder metallurgy at 350–750 MPa compaction pressures, followed by sintering at 850 °C for 1 and 2 h. Green densities increased from 7.94 to 9.19 g/cm 3 when compaction pressure increased. After sintering, density increased from 8.41 g/cm 3 (1 h) to 9.27 g/cm 3 (2 h), reducing porosity from 23.1 % to 15.3 %. The highest Vickers hardness was 69 HV at 750 MPa and 2 h. SEM/EDS analysis demonstrated consistent tungsten distribution and improved interparticle bonding with longer sintering times. A 58.8 µm thick Sn coating was electrodeposited at a constant current of 0.01 A. Electrochemical experiments in 3.5 % NaCl demonstrated that the corrosion rate reduced from 2.319 mm/year uncoated samples to 0.103 mm/year for coated samples, with scratched coatings yielding an intermediate value of 1.412 mm/year. The enhanced corrosion resistance is due to the galvanic protection given by the tin layer. These findings show that Sn-coated brass/40 wt.% W composites improve densification, mechanical performance, and corrosion resistance in laboratory circumstances, making them potential candidates for substituting lead-based materials in marine environments.