WC Grains Research Articles

L12 strengthening of WC-CoNiFe cemented carbides by spark plasma sintering

Binder phase has very significant effect on the growth of WC grains, grain morphology, the microstructure and properties of cemented carbide. In this paper, Co, Fe and Ni were used as binder phase, cemented carbides with different sintering temperatures were prepared by spark plasma sintering. The differences in the microstructure and properties of 10Co and 8Co-3NiFe were analyzed. The results showed that the 8Co-3NiFe cemented carbide generated the highly ordered FeNi3 phase with FCC of L12. The addition of Fe and Ni decreases the melting point of 8Co-3NiFe, makes the grain morphology of WC more rounded and more homogeneous distribution of the cemented carbide microstructure. The WC grain sizes of the 10Co and 8Co-3NiFe cemented carbides are very similar, but the 8Co-3NiFe cemented carbide shows a slight increase in grain size. Low-temperature densification of the 8Co-3NiFe cemented carbide can be achieved at sintering temperature of 1050°C. The fracture toughness of the 8Co-3NiFe cemented carbide improves by about 10% compared to the 10Co cemented carbide.

A new process for preparing ultrafine WC-Co cemented carbide by doping yttrium within the ammonium metatungstate solution

Ultrafine WC-Co cemented carbide has superior performance of high strength and high hardness, which is widely used in industrial fields. In the traditional process, high temperature carburization method is used to prepare tungsten carbide, and solid-phase mechanical milling method is used to mix grain growth inhibitor (Cr3C2) and tungsten carbide, which easily lead to large WC particle size and uneven WC grain size distribution in WC-Co cemented carbide, thus affecting mechanical properties of the alloy. In the new process, based on the genetic relationship between the particle size of ammonium paratungstate and tungsten carbide, ultrafine ammonium paratungstate uniformly doped with yttrium was firstly obtained by adding a certain amount of ammonia and yttrium oxide into the ammonium metatungstate solution. Then the ammonium paratungstate was calcined to obtain yttrium-doped tungsten trioxide, which was then converted into yttrium-doped ultrafine tungsten carbide powders by introducing carbon monoxide at a low temperature. Finally, the ultrafine WC-Co cemented carbide was prepared by pressure sintering. During the neutralization and crystallization process of ammonium metatungstate solution, the yttrium-doped ultrafine ammonium paratungstate (Fischer particle size 8.4 μm) with narrow particle size distribution and regular morphology was prepared. The yttrium-doped ammonium paratungstate was calcined at 500 °C for 90 min in air atmosphere to obtain yttrium-doped tungsten trioxide powder with a Fischer particle size of 4.5 μm and narrow size distribution. Then the yttrium-doped tungsten trioxide and carbon monoxide gas were reacted at 920 °C for 3h to obtain yttrium-doped ultrafine tungsten carbide powder with a Fischer particle size of 0.32 μm and a specific surface area of 4.44 m2/g, and ultrafine WC-Co cemented carbide with tungsten carbide grain size of 0.28 μm was obtained by pressure sintering. The yttrium uniform distributed effectively inhibited the abnormal growth of tungsten carbide grains. Compared with the WC-Co cemented carbide prepared by solid-phase mechanically mixing tungsten carbide powder and chromium carbide, the yttrium-doped WC-Co cemented carbide had a smaller average tungsten carbide grain size and a more homogeneous microstructure. The prepared yttrium-doped WC-Co cemented carbide had a hardness (HRA) of 94.6, a bending strength of 4841 M, and a coercive force of 42.3 KA/c.

Effect of oscillation frequency on microstructure and properties of WC-Co cemented carbide prepared by hot oscillating pressing

In this study, a novel hot oscillating pressing (HOP) was used to prepared WC-Co cemented carbides under various oscillation frequencies. The effects of sintering frequencies on the density, microstructure, and mechanical properties of cemented carbides were systematically investigated. The results show that applying a specific oscillation frequency during the sintering process can greatly aid in the densification process, improve the uniformity of microstructure, help the grain refinement, and prevent the formation of abnormally large WC grains. The mechanical properties of the alloys showed a noticeable improvement as the oscillation frequency increased. The hardness and fracture toughness of cemented carbides were not significantly improved when the oscillation frequency was ≥5 Hz, with the optimal values reaching 1913 kg/m2 and 13.11 MPa.m1/2, in turn. The improvement in mechanical properties of cemented carbide can be mainly attributed to higher density, grain refinement, microstructure uniformity and the increase of dislocation/twins caused by plastic deformation.

Microstructures and properties of a novel cemented carbide prepared using a Co–Ni–Cu multiprincipal element alloy as the binder

A Co–Ni–Cu multiprincipal element alloy (MPEA) powder was successfully synthesized through coprecipitation. Results of energy dispersive spectroscopy (EDS) and X-ray fluorescence spectroscopy (XRF) revealed nearly equal atomic ratios for Co, Ni, and Cu in the Co–Ni–Cu MPEA powder. Moreover, X-ray diffraction (XRD) confirmed a single-phase face-centered cubic (fcc) structure in the Co–Ni–Cu MPEA powder. To explore the differences in microstructure and mechanical properties, we compared a novel WC–2Co–2Ni–2Cu cemented carbide, utilizing the Co–Ni–Cu MPEA as a binder, with conventional WC–6Co and WC–3Co–3Ni cemented carbides prepared via liquid phase sintering. This comparison was conducted using scanning electron microscopy, XRD, and mechanical properties testing. Observations revealed that the surfaces of WC grains in WC–2Co–2Ni–2Cu and WC–6Co appeared smooth and flat, while those in WC–3Co–3Ni exhibited roughness with numerous terraces. In addition, the average grain size was 0.96, 1.14, and 1.22 μm in WC–2Co–2Ni–2Cu, WC–6Co, and WC–3Co–3Ni, respectively. Notably, the Co–Ni–Cu MPEA inhibited WC grain growth. WC–2Co–2Ni–2Cu (1388 HV30) exhibited hardness similar to that of WC–6Co (1406 HV30) but the highest fracture toughness (9.04 MPa∙m1/2), while WC–3Co–3Ni (1332 HV30) presented the lowest hardness. Bending strength values were recorded at 2406 MPa for WC–2Co–2Ni–2Cu, 2816 MPa for WC–6Co, and 2645 MPa for WC–3Co–3Ni, with WC–6Co exhibiting the highest bending strength. Considering their microstructures, physical properties, and mechanical properties comprehensively, the novel cemented carbides exhibited only slightly reduced bending strength compared to conventional counterparts. Thus, the Co–Ni–Cu MPEA binder demonstrates promising potential as a replacement for the conventional Co metal binder.

Preparation of ultrafine WC-V8C7-Cr3C2-co cemented carbides by spark plasma sintering in-situ synthesis of composite grain growth inhibitors

The growing high-precision manufacturing industry is increasing the demand for cemented carbide which has fine grain size and excellent machinability. In this research, ultrafine cemented carbide was successfully prepared by the method of in-situ synthesis using spark plasma sintering as densification method, V, Cr, WC and carbon black as raw materials. The formation mechanism of in-situ preparation of grain growth inhibitors (GGIs) and its influence on the properties of alloys were investigated. An excellent mechanical property (HV 2254 kgf/mm2, KIC 9.20 MPa·m1/2) and uniform microstructure of the alloys (0.8 wt% V8C7–0.8 wt% Cr3C2) prepared under 1350 °C, 6 min, 25 MPa were demonstrated by the results. The WC grain growth was significantly inhibited (about 200 nm). The in-situ synthesized GGIs significantly inhibited grain coarsening by interfering with the dissolution-precipitation process of WC during liquid-phase sintering. The combination of SPS and in-situ synthesized GGIs offers a novel approach to exploration of the preparation of high-performance ultrafine or nanocrystalline cemented carbides.

Influences of Ni/Cu/Cr3C2 composite additive on microstructure and properties of WC–10Co fine grained hardmetal

Aiming to save the high-priced Co resource, Ni, Cu and Cr3C2 were simultaneously used to modify WC–10Co fine grained hardmetal, and the effects of sintering temperature on microstructure, mechanical properties were investigated. The combined introduction of Cu/Cr3C2 can significantly inhibit the growth of WC grains caused by Ni. When sintered at 1420 °C, the hardness, strength and fracture toughness of WC–0.5Cr3C2–(5.4Co3.6Ni1Cu) alloy reach to 1652 HV30, 3301 MPa and 12.01 MPa·m1/2, respectively, which are higher than those of WC–10Co alloy (1601 HV30, 3193 MPa and 11.75 MPa·m1/2). In term of corrosion resistance, Ni and Cr3C2 can eliminate the adverse effect caused by Cu, as evidenced by the decreased passivation current density (Ipp) and the increased charge-transfer resistance (Rct). In this regard, Ni/Cu/Cr3C2 composite additive would be an effective method to conduct the partial replacement of Co by other low-priced metals without sacrificing the mechanical properties and the corrosion resistance of WC–Co hardmetal.

Effect of carbon content on the microstructure and mechanical properties of ultrafine WC-15Co cemented carbides using a Co-based solid solution binder phase

In this paper, a new method was proposed to improve the uniformity of the distribution of grain-growth inhibitors using a Co-based solid solution prepared with Co3O4, Cr2O3, and V2O5 as the raw materials through high-temperature hydrogen reduction. The effect of carbon content on the microstructure and mechanical properties of ultrafine WC-15Co cemented carbides using a Co-based solid solution binder phase were studied. The results demonstrated that the carbon content exerted a considerable influence on the composition of the binder phase, thereby affecting the morphology of the WC grains. With increasing the carbon content, Cr and V precipitated from the Co-based solid solution, adhering to the habit planes of WC or segregating at the WC-Co interface. This hindered the growth of WC grains, yielding an average particle size smaller than that of alloys containing 6.0wt.% carbon content. However, increased carbon content may enhance grain growth owing to the dissolution-precipitation process of WC grains during the liquid-phase sintering process. Thus, an alloy comprising 6.31wt.% carbon content and featuring trigonal prismatic-shaped WC grains with a mean particle size of 0.310 μm exhibited excellent comprehensive performance, characterized by a hardness, transverse rupture strength, and fracture toughness of 1579kg/mm2, 2581MPa, and 10.56MPa·m1/2, respectively.

The microstructure evolution and mechanical properties of WC-cu-10Ni-5Mn-3Sn cemented carbides containing NbC prepared by pressureless melt infiltration

WC-based cemented carbides with different contents of NbC (0, 0.6, 0.8, 1.0, 1.2, and 1.4 wt%) are prepared via pressureless melt infiltration at 1200 °C for 1.5 h. Microstructure evolution regularity of WC-based cemented carbide is investigated to establish the effect of NbC addition and microstructure peculiarities on mechanical properties (flexural strength, hardness, and impact toughness) of final product. Experimental results reveal that NbC firstly dissolves in binder alloy during melt infiltration, which slows down dissolution-precipitation reaction of WC, thus refining WC grains. With the increase in NbC content, average WC grain size shows varying trend, achieving the minimum (3.779 μm) at NbC addition of 1 wt%. When NbC is added in smaller amounts, Nb is mainly distributed throughout binder alloy. With the increase in NbC content, Nb elements tend to form aggregates and attach to WC particle boundaries. Some WC and NbC also decompose under experimental conditions. At NbC addition greater than 1 wt%, decomposition products (Nb, W, and C) combine with other elements in binder phase to form new phases such as (Nb,W)C, Ni2W4C, Nb2C, and Nb4Ni2C. These phases further act as bridges for WC grain coarsening. Meanwhile, excessive NbC is detrimental to mechanical properties of the alloy. With the increase in NbC content, hardness and flexural strength of the alloy increase and then decrease, reaching the maximum values of 93.4 HRA and 1808.786 MPa, respectively, at 1 wt% NbC addition. In turn, impact toughness of the alloy shows consistently downward trend. Therefore, changes in mechanical properties of WC-based cemented carbides are mainly related to WC grain size, the appearance of new phases in binder phase, and their morphology.

Densification and properties of WC-CoCrFeNi/Co cemented carbide fabricated via spark plasma sintering

The spark plasma sintering (SPS) technique was used to employe WC-CoCrFeNi/Co cemented carbides, incorporating CoCrFeNi and Co as low-coercivity binder phases, resulting in the development of cemented carbides with exceptional mechanical properties. The densification mechanism varying with increasing sintering temperature and the effect of densification on the mechanical properties were investigated using the creep deformation model. In the temperature range of 1100 °C–1300 °C, the main factors contributing to densification behavior are particle rearrangement and grain boundary diffusion due to the viscous flow of the binder phase. The densification mechanism gradually transforms into dislocation climbing with increasing temperature. When the sintering temperature exceeded 1300 °C, the WC grain size increased significantly with increasing temperature and holding time, and the dominant mechanism for grain growth was grain boundary diffusion. The high densification resulted in a substantial increase in effective grain boundary area, thereby increasing both hardness and fracture toughness of the material. Benefiting from the fine grain strengthening effect of the high-entropy alloys (HEAs) and the excellent wettability of Co, a highly dense cemented carbide material with excellent hardness and fracture toughness is achieved at the sintering temperature of 1300 °C, characterized by a relative density of 99.3 %, a hardness of 2064.9 MPa, and a fracture toughness of 11.5 MPa m−2.

Effect of HVOF method spraying parameters on phase composition and mechanical and tribological properties of 86WC-10Co-4Cr coating

Valve components used in the petroleum industry are subjected to intense wear during operation, which leads to a sharp decrease in their durability. Usually, the often subjected to the wear process surface of the valves is treated by tungsten carbide cladding to improve its durability. Because of the difficulty in applying tungsten carbide using conventional surfacing techniques, high velocity oxyfuel (HVOF) spraying technology is rec- ommended. In this work, the mechanical, tribological properties and phase composition of 86WC-10Co-4Cr composition coatings obtained by HVOF Termika-3 high-velocity gas-fuel spraying were investigated. Vary- ing the technological parameters of spraying was carried out by changing the spraying distance, which led to differences in the thickness of the coatings. The phase composition, microstructure and distribution of ele- ments were analyzed using X-ray diffraction (XRD), scanning electron microscopy (SEM) methods. The hardness of the samples was measured on a microhardness tester using the Vickers method, the friction coef- ficient and the wear rate were investigated using a friction and wear tester. It was determined that the surface of the coatings had developed character and high roughness. The results of X-ray phase analysis showed the predominance of hexagonal WC as the major phase, with a small amount of hexagonal tungsten carbide W2C as the minor phase, and the minor presence of cobalt oxide CoO. It was found that the increased wear re- sistance and low friction coefficient of 86WC-10Co-4Cr coatings are explained by the high volume fraction of hard and stable WC grains with high resistance to wear.

Coarse-grained WC–6Co hardmetals with dual-scale and plate-like WC structures fabricated by convention powder metallurgy process

In this work, coarse-grained WC–6Co hardmetals featuring dual-scale and plate-like structures were successfully fabricated via conventional powder metallurgy process using W, ultrafine WC, Co and carbon black as raw materials. The investigation focuses on the effects of two critical factors, sintering temperature and ultrafine WC powder content, on the microstructures, densities, and mechanical properties. The results demonstrate that increasing the sintering temperature accelerates the growth of WC grains via 2D nucleation growth mechanism, thus enhancing the plate-like structure of WC grains. The addition of ultrafine WC powder reduces the mean WC grain size and eliminates the preferential orientation of WC grains because of its separating effect on coarse WC grains. Moreover, the dual-scale and plate-like structures can be achieved with sufficient ultrafine WC content (≥ 20 wt%) and adequate sintering temperature (≥ 1500 °C). Notably, the coarse-grained WC–6Co alloy sintered at 1550 °C with the addition of 20 wt% ultrafine WC powder exhibits good comprehensive mechanical properties: hardness of 1493 ± 7 HV30, transverse rupture strength of 2698 ± 58 MPa and fracture toughness of 16.93 ± 0.65 MPa·m1/2.

Insight into Grain Refinement Mechanisms of WC Cemented Carbide with Al0.5CoCrFeNiTi0.5 Binder.

High-entropy alloys (HEA) as a kind of new binder for cemented carbide have garnered significant attention. In this work, WC/(17~25 wt.%)Al0.5CoCrFeNiTi0.5 cemented carbides were prepared by hot pressing sintering (HPS), and the reactions between WC powder and Al0.5CoCrFeNiTi0.5 powder during hot pressing sintering were elucidated. It found that different from traditional Co binder, the Al0.5CoCrFeNiTi0.5 binder effectively inhibited WC grain growth. During HPS, the decomposed W and C atoms from WC diffused into the Al0.5CoCrFeNiTi0.5 binder, reacted with the elements in the binder, and then formed the M(Co, Fe, Ni)3W3C phase. The back-diffusion of W and C atoms to WC grains was restricted by the Al0.5CoCrFeNiTi0.5 alloy and inhibited them from re-precipitating onto the large undissolved WC grains. As a result, the average size of WC grains in the cemented carbides was less than 200 nm. This work bright new insight into the grain refinement mechanisms of WC cemented carbide with HEA binder and provide a guidance for designing performance-stable WC/HEA cemented carbide and promoting their application.

Microstructural evolution and mechanical behavior of WC–4wt.%TiC–3wt.%TaC–12wt.%Co refractory cermet consolidated by spark plasma sintering of mechanically activated powder mixtures

The paper studied the structural features and physicomechanical properties of the WC–4wt.%TiC–3wt.%TaC–12wt.%Co composite refractory hard alloy system obtained by spark plasma sintering (SPS) from a preliminarily mechanically activated powder. It has been shown that preliminary mechanical activation in a planetary mill contributed to the comminution of agglomerates and the formation of a monomodal particle size distribution with a predominance of the submicron fraction, which intensifies the densification processes during subsequent consolidation by the SPS method. Kinetic analysis of the SPS process showed a two-stage sintering pattern with intense densification at temperatures above 790 °C due to rearrangement of WC, TiC, TaC particles and melting of the cobalt binder. It has been found that the SPS method does not lead to the formation of undesirable secondary phases in the entire sintering temperature range. A sintering temperature of 1200 °C is optimal for achieving the best structural homogeneity, density and mechanical properties, providing optimal distribution of carbide phases and the cobalt binder. The microstructure of the sample obtained at 1200 °C represents a refractory skeleton of WC grains with TiC and TaC carbide particles uniformly distributed throughout the volume. Improved fluidity of the melted cobalt binder and its mobile redistribution contribute to increased compactness of the structure and reduced porosity of the material. Samples sintered at 1200 °C possess high physicomechanical characteristics: relative density 99.99 %, hardness HV30 1623.2, bending strength 1125.1 MPa, fracture toughness 10.5 MN⋅m1/2. The abrasive wear resistance of a newly synthesized hard material was evaluated through a turning operation. Results showed durability, indicating promise for cutting tool applications and the need for further research to fully characterize the performance of this novel material.

Effect of Cr3C2 Addition on Microstructure and Mechanical Properties of WC-CoNiFe Cemented Carbides

In traditional cemented carbides, Co is mainly used as a binder. Recently, replacing Co with medium- to high-entropy alloys has shown significant improvements in hardness, fracture toughness, high-temperature oxidation resistance, and corrosion resistance, making it a research focus globally. Both the typical grain refiner Cr3C2 and medium- to high-entropy alloy binders affect the WC grain size in cemented carbides. This study investigates the synergistic grain refinement mechanism of Cr3C2 and medium- to high-entropy alloy binders on WC grains and their impact on the microstructure and mechanical properties of cemented carbides. The results show that increasing the Cr3C2 addition refined WC grains in the WC-CoNiFe alloy, increased coercivity, and enhanced hardness, with transverse rupture strength first increasing and then decreasing. The alloy achieved optimal performance at 0.6 wt.%Cr3C2, with a hardness of 91.25 HRA and transverse rupture strength of 3883.2 MPa.

Understanding tool cutting-edge microstructure and deformation mechanism induced by adhesive wear in the turning of nickel-based superalloys

Nickel-based superalloy has great potential in the aerospace industry as key components. However, difficult-to-machine characteristics have further limited its application. Thermal-barrier coatings of the titanium-based family on carbide tools offer exceptional performance in cutting superalloys, combining high-temperature stability and remarkable toughness. This work primarily concentrates on understanding cutting-edge microstructure and deformation induced by tool adhesive wear in the turning of nickel-based superalloys with experiment and modelling. The dominant tool wear mechanisms are revealed to be adhesive wear and abrasive wear by SEM/EDS. The microstructure of the cutting-edge interface is qualitatively and quantitatively investigated by SEM/EDS and EBSD. The adhesive layer thickness at cutting edge is about 10–30 μm. The GND density of WC grains at cutting edge is 15-20 × 1014/m. The nanomechanics properties of the tool wear interface were quantitatively evaluated by nanoindentation. The average hardness of WC and Ni-superalloy at cutting-edge interface is evaluated to be 15–19 GPa and 6.2–6.5 GPa, respectively. Further, the underlying deformation mechanisms induced by tool wear behaviours are revealed through the transient heat conduction model and cutting-edge stress distribution model. This research offers a framework and mechanism for the cutting tool wear surface/interface characteristics targeted to the difficult-to-cut superalloy materials.

Feasible production of highly homogeneous nano-scaled WC powders: An industrial practice via raw material pretreatment and direct reduction-carbonization

A method for industrial production of nano-scaled WC powders has been proposed. In this work, WO2.9 is subject to pre-reduction, followed by jet-milling treatment. The precursor is then mixed with carbon black by ball milling, and directly reduced-carbonized to nano-scaled WC powders. The WC powders prepared at different carbonization temperatures were made into alloys and micro drills, revealing the influence of powder properties on the microstructure and properties of the alloys through comparative analysis. The results indicate that when WO2.9 powder is reduced at 700 °C for 1h and then jet-milled at a rotational speed of the grading wheel of 3500 rpm, the aggregates in the powder can be effectively broken, and the precursor powders with fine particle size and near-single phase can be obtained. In this way, the equipment exhibits relatively high productivity. By comparing the microstructure and properties of the alloy prepared from raw materials at different carbonization temperatures, it can be seen that if the carbonization temperature is too high, the average particle size of the powder increases and agglomeration appears in the microstructure. An increase in the average particle size of the powder will lead to an increase in the average grain size of the prepared alloys, thereby reducing the hardness and the wear resistance during service. In addition, the agglomerated particles in the powders can easily lead to abnormal WC grain growth in the microstructure of the prepared alloys, which reduces the bending strength.

Arc-enhanced glow discharge ion etching of WC-Co cemented carbide for improved PVD thin film adhesion and asymmetric cutting edge preparation of micro milling tools

Wear-resistant thin films on cutting tools require effective ion etching to enhance adhesion and thus extended tool service life. Arc enhanced glow discharge (AEGD) ion etching, characterized by high ionization degrees and high etch rates, was applied to ultrafine-grained WC-Co cemented carbide, commonly used for micromilling cutters. The effect of AEGD ion etching on the surface integrity of WC-Co and the resulting adhesion behavior of a TiAlSiN thin film was investigated by varying the etching time in comparison with conventional glow discharge (GD) ion etching. In addition, the impact of intensive etching on the cutting edge geometry of micro end cutters and, in turn, on the cutting performance in micromilling of hardened and annealed high-speed steel was evaluated.AEGD achieves remarkable etch rates of 12 nm/min at extended etching times, which are 100 times greater than conventional glow discharge (GD) ion etching. Prolonged AEGD ion etching for ≥30 min removes entire near-surface WC grains and exposes carbides beneath, resulting in increased surface roughness. After the etching process, polished WC-Co substrates exhibit a slight reduction in residual compressive stresses, which steadily decrease with increasing AEGD ion etching time. Furthermore, a TiAlSiN thin film demonstrates high adhesion on AEGD-etched surfaces compared to GD ion etching. Even a brief 5 min AEGD ion etching ensures the highest adhesion class according to the Rockwell C indentation test. Moreover, the intensive material removal results in significant changes in cutting edge geometry of micro end cutters, yielding substantial cutting edge rounding and an asymmetrical shape with form-factors Κ ≥ 2. In cutting tests, the resulting cutting edge geometries effectively reduce the wear formation and the associated wear-related increase in process forces during micromilling hardened and tempered powder metallurgical high-speed steel. In summary, AEGD ion etching emerges as a highly effective method for both enhancing thin film adhesion and preparing adapted asymmetrical cutting edge geometries for micromilling tools.

Thermal conductivity loss in WC-Co hard metal due to high-temperature cyclic loading damage as a function of microstructure and temperature

Many structures made of WC-Co hard metal are subject to thermo-mechanical loading and have to conduct heat in order to function properly in industrial application. The current work provides results on a significant drop in thermal conductivity of WC-Co hard metals as a function of material volume damage that accumulates during cyclic high-temperature loading of the materials depending on material microstructure. Average WC grain size and Co binder metal content of the investigated grades ranged from submicron to medium and from 10 to 12 wt%, respectively. The hard metals were subjected to uniaxial cyclic loading in a vacuum for different numbers of load cycles at 700 °C and 800 °C. Damage features accumulated in the material volume were documented by means of scanning electron microscopy. Thermal conductivity properties of virgin and damaged materials were determined via laser flash analysis. The results indicated a significant decrease depending on the materials' microstructure, i.e. the defects' predominant location within the microstructure. The damage features that occurred mainly between WC grains in the coarser-grained grade led to larger drops in thermal conductivity with rising temperature compared to damage features that occurred within the Co binder metal in the finer-grained grade. The presented results are of high relevance to the thermo-mechanical load situation of e.g. milling tools since the heat conduction away from their cutting edges is hindered by the documented effect and deemed to lead to a self-acceleration of the damage accumulation.

Enhancing mechanical properties and density of WC-Co with pressureless sintering via shell structure binder jetting additive manufacturing

The binder jetting (BJT) additive manufacturing (AM) process is suitable for producing complex WC-Co cemented carbide parts. To achieve near-full-density in the final parts, the hot isostatic pressing (HIP) sintering process is typically employed to enhance densification. However, HIP sintering requires high equipment specifications and is relatively more costly compared to conventional pressureless sintering. To improve the density of WC-Co parts printed by BJT AM under the pressureless sintering environment, the shell structure printing method was used in this study. The shell structure printing only jets binder to the model's outer profile, creating a shell that encapsulates the central powder, mitigates binder pyrolysis and residual effects on particle densification, and enhances post-sintering density. In this work, the effect of shell thickness, binder type, and printing layer thickness on the density and mechanical properties of the WC-12Co parts under pressureless sintering conditions were investigated. The results show that the density and mechanical properties of the WC-12Co parts significantly improved with the decreasing shell thickness. Specifically, the WC-12Co printed using shell structure achieves a relative density of over 98% and a transverse rupture strength (TRS) of 1954 MPa after pressureless sintering, a result comparable to BJT printed samples treated with HIP sintering. Moreover, the results indicate using a binder with lower residual carbon content and smaller printing layer thickness has a more positive effect on improving density and mechanical strength when employing the shell structure printing method. Microstructure morphology and phase analysis results indicate that the shell structure printing method does not affect the growth of WC grains in the shell and center regions, nor does it influence its phase composition. The shell structure printing method offers a new approach to the manufacturing of near-full-dense WC-Co materials using the BJT process.

Effect of grain size and cobalt content on machining performance during milling tungsten carbide with PCD tool

Tungsten carbide has been extensively utilized in the manufacturing field due to its exceptional properties. However, traditional methods such as grinding or electric discharge machining often result in a low material removal rate and inevitable surface defects, making tungsten carbide one of the most challenging materials to machine. Milling has emerged as a promising alternative for machining tungsten carbide. However, the milling of tungsten carbide has not been widely applied in the industry due to a lack of comprehensive understanding regarding the milling performance of different tungsten carbides under various conditions. In this paper, a polycrystalline diamond (PCD) tool was used in the milling of tungsten carbides to investigate the effects of tool grain size, workpiece Co content, and WC grain size on tool wear and machining surface quality. It was found that PCD tools with larger grain sizes exhibited higher wear resistance. Additionally, excessive Co content in the workpiece and large WC grain size increased tool wear and degraded the quality of the machined surface. The primary types of tool wear observed in the milling of WC-Co included adhesive wear, abrasive wear, phase change wear, and oxidation wear.