Effect of Metal Elements on Microstructure and Mechanical Properties of Ultrafine Cemented Carbide Prepared by SPS

To satisfy the needs of precision machining, ultrafine tungsten carbide (WC)-based cemented carbide with fine grain size and excellent mechanical properties was prepared. Ultrafine cemented carbide was prepared by spark plasma sintering (SPS) using WC, Co as raw materials and metal elements V, and Cr as additives, and the effects of metal elements on the microstructure and mechanical properties of cemented carbide were investigated. The results show that the specimen (91.6WC-1.2V-1.2Cr-6Co) prepared at 1350 °C, 6 min, 25 MPa has the best mechanical properties (HV 2322.9, KIC 8.7 MPa·m1/2) and homogeneous microstructure. The metal elements could react with WC to form a (W, V, Cr) Cx segregation layer, which effectively inhibits the growth of WC grains (300 nm). The combination of SPS and metal element additives provides a new approach for the preparation of ultrafine cemented carbides with excellent properties.

Improving Wear Resistance and Corrosive Resistance of Cemented Carbide for Mud Pulser Rotor by Deep Cryogenic Treatment

Cemented carbide used in the rotor of a mud pulser is subjected to the scouring action of solid particles and corrosive mud media for a long time, which causes abrasive wear and electrochemical corrosion. To improve the wear and corrosive resistance of cemented carbide, samples with different cobalt content (WC-5Co, WC-8Co, and WC-10Co) receive deep cryogenic treatment (DCT) at -196 °C for 2.5 h. An optical metalloscope (OM) and X-ray diffractometer (XRD) are used to observe the phase changes of cemented carbides, and the XRD is also used to observe the change in residual stress on the cemented carbide's surface. A scanning electron microscope (SEM) is used to characterize the wear and electrochemical corrosion surface microstructure of cemented carbides (untreated and DCT). The results show that the DCT promotes the precipitation of the η phase, and the diffraction peak of ε-Co tends to intensify. Compared with the untreated, the wear rates of WC-5Co, WC-8Co, and WC-10Co can be reduced by 14.71%, 37.25%, and 41.01% by DCT, respectively. The wear form of the cemented carbides is mainly the extrusion deformation of Co and WC shedding. The precipitation of the η phase and the increase in WC residual compressive stress by DCT are the main reasons for the improvement of wear resistance. The electrochemical corrosion characteristic is the dissolution of the Co phase. DCT causes the corrosion potential of cemented carbide to shift forward and the corrosion current density to decrease. The enhancement of the corrosion resistance of cemented carbide caused by DCT is due to the Co phase transition, η phase precipitation, and the increase in the compressive stress of cemented carbide.

Comparative Study on the Densification, Microstructure and Properties of WC-10(Ni, Ni/Co) Cemented Carbides Using Electroless Plated and Coprecipitated Powders

More and more attention is being paid to the influence of powder mixing on the mechanical properties and corrosion resistance of WC-based cemented carbides. In this study, WC was mixed with Ni and Ni/Co, respectively, by chemical plating and co-precipitated-hydrogen reduction, which are labelled as WC-Ni^EP, WC-Ni/Co^EP, WC-Ni^CP and WC-Ni/Co^CP, respectively. After being densified in a vacuum, the density and grain size of CP were denser and finer than those of EP were. Simultaneously, the better mechanical properties of flexural strength (1110 MPa) and impact toughness (33 kJ/m²) were obtained by WC-Ni/Co^CP due to the uniform distribution of WC and binding phase and solid solution enhancement of the Ni-Co alloy. In addition, the lowest self-corrosion current density of 8.17 × 10^-7 A·cm^-2, a self-corrosion potential of -0.25 V and the biggest corrosion resistance of 1.26 × 10⁵ Ω in 3.5 wt % NaCl solution were obtained by WC-Ni^EP because of the presence of the Ni-Co-P alloy.

Polishing Characteristics of Cemented Carbide Using Cubic Boron Nitride Magnetic Abrasive Powders

This paper describes the application of bonded magnetic abrasive powders (MAPs) in the magnetic abrasive finishing (MAF) process. In order to improve the poor finishing performance and short service life of MAPs in polishing super-hard materials, a double-stage atomization technique was used to successfully manufacture MAPs with a CBN as an abrasive phase. The prepared results show that CBN abrasives with their original structure were deeply and densely embedded on the surface of spherical MAPs. Based on the MAF process, a five-level and four-factor central composite design experiment was carried out to verify the developed MAPs polishing performance on the finishing of cemented carbide parts (864 Hv). Working gap, rotational speed, feed rate of a workpiece, and mesh number of MAP were considered as influence factors. The analysis data was used to understand different interactions of significant parameters. A regression model for predicting the change of surface roughness was obtained, and the optimal parameter combination was figured out through a solution of a quadratic equation in Design-Expert software. According to MAF results, the strong cutting ability of atomized CBN MAPs improved the surface roughness of cemented carbide by over 80% at the optimum parameters. The strong cutting ability of atomized CBN MAPs can produce good surface quality on the hard materials. The findings of this research can promote a large-scale application of MAF technology in the surface polishing of hard materials.

Effect of Textured Dimples on the Tribological Behavior of WC/Co Cemented Carbide in Dry Sliding with Al2O3/WC Ceramic

Micro-dimples were fabricated on the surface of WC/Co cemented carbide disks by laser, and dry friction tests were carried out by sliding with Al₂O₃/WC ceramic balls. Results show that the textured cemented carbide can reduce the average friction coefficient by about 30% compared to the smooth sample, while the textured cemented carbide with solid lubricants can reduce the average friction coefficient by about 50%. The density of textured dimples has no obvious influence on the friction coefficient. The wear rates of worn ceramic balls continue to decline with the increase in sliding speeds. The wear rates of the ceramic balls can be reduced by 40~50% for textured samples and about 65% for textured samples with solid lubricants compared to the untextured ones. The mechanism for improving the tribological properties of cemented carbide materials is that the textured dimples can store lubricants and capture wear debris, which would play an important role in promoting the engineering application of surface texturing in cemented carbide materials.

Surface texture and fractal analysis of cemented carbide cutting tools

This work highlights the usefulness of multi-scale-fractal and surface-texture analysis in the machining of cemented carbide cutting edge by electrolytic-abrasive honing (EAH) process. In order to achieve this, a fresh (untreated) cutting edge sample and the same sample after machining by electrolytic-abrasive honing (treated) were studied upon their characteristics of surface texture and material properties to provide manufacturers a sustainable advantage in strengthening their tools. The surface characteristics of untreated and honed samples have been analyzed by evaluating four similar locations in the regions of each sample. Scanning electron microscopy (SEM) has been used for the characterization of materials surface. It was found that the unprepared cutting edge and the electrolytic-abrasive sharp surface regions of the samples could be distinguished by area scale analysis and surface texture characteristics. The present study will help in improving the life span estimation of the tools and highlight the opportunities for the statistical modeling of lubrication mechanisms between the tool and the workpiece.

A Finite Element Analysis of the Effects of Graphene and Carbon Nanotubes on Thermal Conductivity of Co Phase in WC-Co Carbide

In engineering practice, the service life of cemented carbide shield tunneling machines in uneven soft and hard strata will be seriously reduced due to thermal stress. When carbon nanotubes (CNTs) and graphene nano-platelets (GNPs) are added to WC–Co carbide as enhanced phases, the thermal conductivity of carbide is significantly improved. Research should be performed to further understand the mechanism of enhancement in composites and to find ways to assist the design and optimization of the structure. In this paper, a series of finite element models were established using scripts to find the factors that affect the thermal conduction, including positions, orientations, interface thermal conductivity, shapes, sizes, and so on. WC–Co carbide with CNTs (0.06%, 0.12%, and 0.18% vol.), GNPs (0.06%, 0.12%, and 0.18% vol.) and hybrid CNTs–GNPs (1:1) were prepared to verify the reliability of finite element simulation results. The results show that the larger the interface thermal conductivity, the higher the composite phase thermal conductivity. Each 1%vol of CNTs increased the thermal conductivity of the composite phase by 7.2%, and each 1% vol. of GNPs increased the thermal conductivity of the composite phase by 5.2%. The proper curvature (around 140°) of CNTs and GNPs with a proper diameter to thickness ratio is suggested to lead to better thermal conductivity.

Vat Photopolymerization of Cemented Carbide Specimen

Numerous studies show that vat photopolymerization enables near-net-shape printing of ceramics and plastics with complex geometries. In this study, vat photopolymerization was investigated for cemented carbide specimens. Custom-developed photosensitive WC-12 Co (wt%) slurries were used for printing green bodies. The samples were examined for defects using quantitative microstructure analysis. A thermogravimetric analysis was performed to develop a debinding program for the green bodies. After sintering, the microstructure and surface roughness were evaluated. As mechanical parameters, Vickers hardness and Palmqvist fracture toughness were considered. A linear shrinkage of 26–27% was determined. The remaining porosity fraction was 9.0%. No free graphite formation, and almost no η-phase formation occurred. WC grain growth was observed. 76% of the WC grains measured were in the suitable size range for metal cutting tool applications. A hardness of 1157 HV10 and a Palmqvist fracture toughness of 12 MPam was achieved. The achieved microstructure exhibits a high porosity fraction and local cracks. As a result, vat photopolymerization can become an alternative forming method for cemented carbide components if the amount of residual porosity and defects can be reduced.

Effects of Different Substrates on the Formability and Densification Behaviors of Cemented Carbide Processed by Laser Powder Bed Fusion

Cemented carbide materials are widely applied in cutting tools, drill tools, and mold fabrication due to their superior hardness and wear resistance. Producing cemented carbide parts via the laser powder bed fusion (L-PBF) method has the advantage of fabricating complex structures with a rapid manufacturing speed; however, they were underdeveloped due to their low density and crack formation on the blocks. This work studied the effect of different substrates including 316L substrates, Ni200 substrates, and YG15 substrates on the forming quality of WC-17Co parts fabricated by L-PBF, with the aim of finding the optimal substrate for fabrication. The results revealed that the Ni200 substrates had a better wettability for the single tracks formation than other substrates, and bonding between the built block and the Ni200 substrate was firm without separation during processing with a large range of laser energy inputs. This guaranteed the fabrication of a relatively dense block with fewer cracks. Although the high laser energy input that led to fine crack formation on the blocks formed on the Ni200 substrate, it was found to be better suited to restricting cracks than other substrates.

Multilayer Diamond Coatings Applied to Micro-End-Milling of Cemented Carbide

Cobalt-cemented carbide micro-end mills were coated with diamond grown by chemical vapor deposition (CVD), with the purpose of micro-machining cemented carbides. The diamond coatings were designed with a multilayer architecture, alternating between sub-microcrystalline and nanocrystalline diamond layers. The structure of the coatings was studied by transmission electron microscopy. High adhesion to the chemically pre-treated WC-7Co tool substrates was observed by Rockwell C indentation, with the diamond coatings withstanding a critical load of 1250 N. The coated tools were tested for micro-end-milling of WC-15Co under air-cooling conditions, being able to cut more than 6500 m over a period of 120 min, after which a flank wear of 47.8 μm was attained. The machining performance and wear behavior of the micro-cutters was studied by scanning electron microscopy and energy-dispersive X-ray spectroscopy. Crystallographic analysis through cross-sectional selected area electron diffraction patterns, along with characterization in dark-field and HRTEM modes, provided a possible correlation between interfacial stress relaxation and wear properties of the coatings. Overall, this work demonstrates that high adhesion of diamond coatings can be achieved by proper combination of chemical attack and coating architecture. By preventing catastrophic delamination, multilayer CVD diamond coatings are central towards the enhancement of the wear properties and mechanical robustness of carbide tools used for micro-machining of ultra-hard materials.

Influence of Cr3C2 and VC Content on WC Grain Size, WC Shape and Mechanical Properties of WC-6.0 wt. % Co Cemented Carbides

In this paper, the influences of Cr₃C₂/VC content on WC grain size, WC grain shape and mechanical properties of WC–6 wt. % Co cemented carbides were investigated. The results showed that the grain size first rapidly decreased and then slightly decreased with the increasing Cr₃C₂/VC content, and VC led to finer grain size and narrower size distribution. HRTEM/EDS analysis of the WC/Co interface indicates that the segregation concentration of V is much larger than that of Cr, which may be a strong response to the higher inhibition efficiency of VC. The addition of Cr₃C₂ induced triangular prism shape WC grains while VC generated stepped triangular prism grains. Despite the grain growth inhibitor (GGI) mechanisms of Cr₃C₂/VC have been extensively studied in the literature, the doping amount, especially the doping limit, has not been systematically investigated. In this work, the saturated solubilities of Cr and V in cobalt binder phase along with carbon content hare been predicted based on thermodynamic calculations. Based on the theoretical calculations, the doping amount of Cr₃C₂/VC is designed to be gradually increasing until more or less over their maximum solubilities in the binder phase, thereby investigating the subsequent microstructure and mechanical properties. When the doping of Cr₃C₂/VC exceeds the maximum solubility in Co phase, Co-rich Cr-carbides and Co-deficient V-carbides would form respectively, which were detrimental to the transverse rupture strength (TRS) and impact toughness. The hardness increased with the increasing Cr₃C₂/VC content, while the fracture toughness decreased with the increasing Cr₃C₂/VC content. The TRS initially enhanced and then declined, but the stepped triangular prism shape grains and low fraction of WC/Co interface in WC–6Co–VC cemented carbide led to a more pronounced decline in the TRS. The sample with 0.6 wt. % Cr₃C₂ addition had good comprehensive mechanical properties, its hardness, fracture toughness and TRS were 1880 kg/mm², 9.32 MPa·m^1/2 and 3450 MPa, respectively.

Influence of Cemented Carbide Composition on Cutting Temperatures and Corresponding Hot Hardnesses

During metal cutting, high temperatures of several hundred-degree Celsius occur locally at the cutting edge, which greatly impacts tool wear and life. Not only the cutting parameters, but also the tool material's properties influence the arising cutting temperature which in turn alters the mechanical properties of the tool. In this study, the hardness and thermal conductivity of cemented tungsten carbides were investigated in the range between room temperature and 1000 °C. The occurring temperatures close to the cutting edge were measured with two color pyrometry. The interactions between cemented carbide tool properties and cutting process parameters, including cutting edge rounding, are discussed. The results show that cemented carbides with higher thermal conductivities lead to lower temperatures during cutting. As a result, the effective hardness at the cutting edge can be strongly influenced by the thermal conductivity. The differences in hardness measured at room temperature can be equalized or evened out depending on the combination of hardness and thermal conductivity. This in turn has a direct influence on tool wear. Wear is also influenced by the softening of the workpiece, so that higher cutting temperatures can lead to less wear despite the same effective hardness.

Experimental Study of Wear Mechanisms of Cemented Carbide in the Turning of Ti6Al4V

Titanium and titanium alloys such as Ti-6Al-4V are generally considered as difficult-to-machine materials. This is mainly due to their high chemical reactivity, poor thermal conductivity, and high strength, which is maintained at elevated temperatures. As a result, the cutting tool is exposed to rather extreme contact conditions resulting in plastic deformation and wear. In the present work, the mechanisms behind the crater and flank wear of uncoated cemented carbide inserts in the turning of Ti6Al4V are characterized using high-resolution scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and high-resolution Auger electron spectroscopy (AES).The results show that, for combinations of low cutting speeds and feeds, crater and flank wear were found to be controlled by an attrition wear mechanism, while for combinations of medium to high cutting speeds and feeds, a diffusion wear mechanism was found to control the wear. For the latter combinations, high-resolution SEM and AES analysis reveal the formation of an approximately 100 nm thick carbon-depleted tungsten carbide (WC)-layer at the cemented carbide/Ti6Al4V interface due to the diffusion of carbon into the adhered build-up layers of work material on the rake and flank surfaces.

Two-Step Spark Plasma Sintering Process of Ultrafine Grained WC-12Co-0.2VC Cemented Carbide

Ultrafine grained WC-12Co-0.2VC (named UYG12V) cemented carbides were prepared via the two-step spark plasma sintering (SPS) in this study. First, the effects of the sintering temperature on the relative density and WC grain size of UYG12V cemented carbides were studied. The results show that regular WC grains form when sintered at 1300 °C. The sintered body begins to rapidly densify and WC grains grow slowly when sintered at 1200 °C. Thus, the first-step (T1) and the second-step (T2) temperatures in the two-step SPS of UYG12V are 1300 °C and 1200 °C, respectively. The effect of the holding time during the first and second steps on the mechanical properties was also studied. The results show that the UYG12V cemented carbide sintered at 1300 °C for 3 min and then at 1200 °C for 5 min has the best comprehensive mechanical properties, exhibiting the average particle size, Vickers hardness, fracture toughness, relative density, and bending strength of 271 nm, 18.06 GPa, 12.25 MPa m^1/2, 99.49%, and 1960 MPa, respectively.

Tribological Characterization of Micron-/Nano-Sized WC-9%Co Cemented Carbides Prepared by Spark Plasma Sintering at Elevated Temperatures

The present study investigates the high temperature tribological performance of spark plasma sintered, nano- and micron-sized tungsten carbide (WC) bonded by 9 wt.% cobalt (Co). The composites were fabricated using a two-step procedure of mixing followed by spark plasma sintering (SPS). Ball-on-disc wear tests were conducted at a normal load of 30 N, linear speed of 0.1 m/s under dry conditions and at three different temperatures (room temperature, 300 °C and 600 °C). Field emission scanning electron microscopy (FESEM), optical profilometry and energy dispersive X-ray (EDS) spectroscopy were used to analyze the surface morphology and the wear track area. At room temperature, it was observed that the nano-sized WC composites exhibited better wear resistance than the micron-sized WC composites. The wear resistance of the nano-sized samples declined significantly relative to that of the micron-sized samples with an increase in temperature. This decline in performance was attributed to the higher surface area of nano-sized WC particles, which underwent rapid oxidation at elevated temperatures, resulting in poor wear resistance. The wear rate observed at 600 °C for the micron-sized WC composites was 75% lower than that of the nano-sized cemented carbide. Oxidative wear was observed to be the predominant wear mechanism for both cemented carbide samples at elevated temperatures.

Experimental Investigation on Direct Micro Milling of Cemented Carbide

Cemented carbide is currently used for various precise molds and wear resistant parts. However, the machining of cemented carbide still is a difficult challenge due to its superior mechanical properties. In this paper, an experimental study was conducted on direct micro milling of cemented carbide with a polycrystalline diamond (PCD) micro end mill. The cutting force characteristics, surface formation, and tool wear mechanisms were systematically investigated. Experimental results show that cemented carbide can be removed with ductile cutting utilizing the PCD tool with a large tool tip radius. Micro burrs, brittle pits, and cracks are the observed surface damage mechanisms. The tool wear process presents microchipping on the cutting edge and exfoliating on the rake face in the early stage, and then severe abrasive and adhesive wear on the bottom face in the following stage.

Fabrication and Tribological Performance of Zr-Coated Carbide against 40Cr Hardened Steel

In order to enhance the tribological performance of YT14 carbide, pure Zr coating was deposited on the substrate surface using a multi-arc ion plating method. The surface topography, adhesion strength, thickness, and micro-hardness of the Zr coating were tested. Dry sliding friction experiments against a 40Cr hardened steel ring were conducted with Zr-coated carbides and traditional ones. The average coefficients of friction were measured and compared. The wear characteristics of the samples were examined by scanning electron microscope (SEM) and energy dispersive X-ray analysis (EDX). The test results indicated that the Zr coating deposited on the carbide surface exhibited excellent adhesive strength and lower hardness. The average friction coefficient of Zr coated carbide decreased by 20%–30% in comparison with that of the uncoated one. The Zr coated carbide could reduce the adhesive wear compared with the uncoated one, and the main tribological degradation mechanisms of the coating were abrasive wear, coating flaking and delamination.

Nanocomposites for Machining Tools

Machining tools are used in many areas of production. To a considerable extent, the performance characteristics of the tools determine the quality and cost of obtained products. The main materials used for producing machining tools are steel, cemented carbides, ceramics and superhard materials. A promising way to improve the performance characteristics of these materials is to design new nanocomposites based on them. The application of micromechanical modeling during the elaboration of composite materials for machining tools can reduce the financial and time costs for development of new tools, with enhanced performance. This article reviews the main groups of nanocomposites for machining tools and their performance.

Cobalt skin dose resulting from short and repetitive contact with hard metals

BACKGROUND

Many daily contacts with metallic items are short and repetitive, and result in metal release; material, sweat, friction and wear may all be important.

OBJECTIVES

To study cobalt release and skin deposition as a result of many short and repetitive contacts with two cobalt-containing materials.

MATERIALS/METHODS

Study participants (n = 5) handled two types of hard metal disc (Co 6% and Co 15% Cr 0.6%) for 30 min. Deposited cobalt skin doses were measured with acid wipe sampling and chemical analysis. Cobalt release from the hard metal discs in artificial sweat was measured under conditions simulating those present during the handling of discs.

RESULTS

Average cobalt skin doses from discs containing 6% Co and 15% Co 0.6% Cr were 1.1 µg/cm(2) [standard deviation (SD) 0.4 µg/cm(2) ] and 0.7 µg/cm(2) (SD 0.5 µg/cm(2) ), respectively. More cobalt was released from hard metal discs containing 6% Co [11.4 µg/cm(2) (SD 1.2 µg/cm(2) )] than from discs containing 15% Co 0.6% Cr [4.8 µg/cm(2) (SD 0.6 µg/cm(2) )]. 10% to 15% of the potentially available cobalt was deposited on the skin during handling.

CONCLUSIONS

It is likely that the cobalt deposited as a result of short and repetitive contact with hard metals may cause harm. Research regarding cobalt exposure, metal release and the deposition of skin-sensitizing metals resulting from short and repetitive contact is needed for a better understanding of the allergy risk.

The Hardness and Strength Properties of WC-Co Composites

The industrially-important WC-Co composite materials provide a useful, albeit complicated materials system for understanding the combined influences on hardness and strength properties of the constituent WC particle strengths, the particle sizes, their contiguities, and of Co binder hardness and mean free paths, and in total, the volume fraction of constituents. A connection is made here between the composite material properties, especially including the material fracture toughness, and the several materials-type considerations of: (1) related hardness stress-strain behaviors; (2) dislocation (viscoplastic) thermal activation characterizations; (3) Hall-Petch type reciprocal square root of particle or grain size dependencies; and (4) indentation and conventional fracture mechanics results. Related behaviors of MgO and Al₂O₃ crystal and polycrystal materials are also described for the purpose of making comparisons.