Part 4: Classification and application fields of cemented carbide
Chapter 12 Cemented Carbide Wear-Resistant Parts and Surface Engineering
12.0 Overview of Cemented Carbide Wear-Resistant Parts and Surface Engineering
Carbide wear-resistant parts play an important role in modern industry due to their excellent mechanical properties and durability. Their high hardness (HV 1600-2500±30), excellent wear resistance (wear rate <0.05 mm³ / N · m ± 0.01 mm³ / N · m ) and excellent impact resistance (impact energy >50 J±5 J) make them the preferred materials for applications such as molds, seals, nozzles, mining drills and surface coatings. The performance parameters of these parts show significant advantages in practical applications, such as mold life of >10 ⁶ times ±10 ⁵ times, seal leakage rate as low as <0.01 mL/min±0.001 mL/min, nozzle flow deviation controlled at <1%±0.1%, mining drill life of more than 100 hours ±10 hours, and surface coating thickness range of 50-500 μm±1 μm . Through geometric optimization (such as stress concentration coefficient K_t <1.3±0.05), thermal spraying technology (such as WC-Co, bonding strength>70 MPa±1 MPa) and surface strengthening technology (such as laser cladding, hardness HV 2000-3000±50), the performance of cemented carbide wear-resistant parts has been significantly improved, and the wear resistance can be reduced by 30%±5%, effectively extending the service life and improving work efficiency.
12.0.1 Concept of Cemented Carbide Wear-Resistant Parts
Cemented carbide wear-resistant parts refer to high-performance wear-resistant parts made by powder metallurgy process with hard phases such as tungsten carbide (WC), titanium carbide ( TiC ) or niobium carbide ( NbC ) as the matrix, supplemented by metal binding phases such as cobalt (Co) and nickel (Ni). These parts have ultra-high wear resistance because their grain size is usually in the range of 0.2-2 microns, and are particularly suitable for industrial applications under high loads, frequent friction or extreme environments. The wear resistance of cemented carbide comes from the balance between its high hardness and appropriate toughness. The hardness value is usually between Vickers hardness (HV) 1600-2500, which is far higher than traditional steel (HV 200-600), and by adding trace elements or composite materials (such as WC-Co system), its impact resistance can reach more than 50 J, which is enough to cope with mechanical shock and thermal stress. The design goal of wear-resistant parts is not only to extend the service life (for example, the mold can withstand millions of stamping cycles), but also to ensure stability under complex working conditions. For example , seals need to maintain a small leakage rate and nozzles need to ensure precise flow. These characteristics make them indispensable in the manufacturing, mining and energy industries.
12.0.2 Definition and significance of surface engineering
Surface engineering is a technology that modifies or coats the surface of materials by physical, chemical or mechanical methods, aiming to improve the wear resistance, corrosion resistance, high temperature resistance or biocompatibility of parts. In cemented carbide wear-resistant parts, surface engineering significantly enhances the surface performance through processes such as thermal spraying, laser cladding, and ion implantation. For example, thermal spraying technology can deposit WC-Co coating on the substrate, with a bonding strength of more than 70 MPa and a thickness controllable within the range of 50-500 microns, significantly improving wear resistance; laser cladding forms a metallurgical bonding reinforcement layer through local melting and rapid solidification, with a hardness of up to HV 2000-3000, and a wear resistance rate reduced by about 30%, effectively extending the life of the parts. The core of surface engineering is to optimize the surface microstructure, reduce stress concentration ( K_t <1.3), improve fatigue resistance, and maintain the overall mechanical properties of the base material. This technology is particularly important in cemented carbide applications, because the surface is the area where the part is in direct contact with the external environment, and its performance directly affects the reliability and service life of the entire component.
12.0.3 Application Background and Development of Cemented Carbide Wear- Resistant Parts and Surface Engineering Technology
The combination of cemented carbide wear-resistant parts and surface engineering technology benefits from the demand of modern industry for efficient and durable equipment. With the development of intelligent manufacturing, green energy and extreme environment mining, the application scenarios of cemented carbide continue to expand. For example, in mold manufacturing, cemented carbide parts meet the needs of high-precision stamping and complex forming through geometric optimization and surface strengthening; in mining drilling, the increase in the life of wear-resistant drill bits directly reduces the replacement frequency and operating costs. Advances in surface engineering technologies, such as nano-coatings and multi-layer composite coatings, have further promoted the application of cemented carbide in high-tech fields, such as aerospace components and medical devices. In addition, combined with digital twin technology and real-time monitoring, surface engineering can achieve dynamic performance optimization and adapt to diverse working conditions.
multiple aspects such as wear-resistant parts, thermal spraying applications, mining and drilling, and surface strengthening technology . By deeply exploring material properties, processing technology, and application scenarios, it aims to provide theoretical support and practical guidance for related industries, especially in performance optimization and innovative applications under high load and high wear environments.
12.1 Cemented Carbide Wear-Resistant Parts
Cemented carbide wear-resistant parts achieve high wear resistance (wear rate <0.05 mm ³ /N · m ± 0.01 mm ³ / N · m ) and long service life (>10 ⁶ times ±10 ⁵ times) through optimized geometric design (radius of curvature> 0.5 mm ± 0.01 mm), material ratio (WC>90%±1%, Co 6%-12% ± 1 % ) and precision processing (sintering temperature 1450°C ± 10 °C) . These parts perform well in industrial environments with high loads and frequent friction. Their performance is due to the balance between the high hardness (HV 1600-2200±30) and appropriate toughness (fracture toughness K ₁ c 10-20 MPa·m ¹ / ² ± 0.5) of cemented carbide materials. Carbide wear-resistant parts are widely used in various fields, including carbide dies (for stamping and forming), carbide seals (for preventing fluid leakage) and carbide nozzles (for precise injection). Their design needs to take into account both wear resistance and impact resistance to meet the needs of diverse working conditions.
12.1.1 Concept of cemented carbide wear-resistant parts
Cemented carbide wear-resistant parts are composite materials sintered by powder metallurgy process with tungsten carbide (WC) as the main hard phase and cobalt (Co) as the binding phase. The WC content is usually more than 90% ± 1%, providing high hardness as a hard skeleton, while the Co content is between 6%-12% ± 1%, which acts as a binding phase to enhance toughness and impact resistance. The best balance between hardness and toughness can be achieved by adjusting the ratio. The sintering process is carried out at a high temperature of 1450°C ± 10°C, using vacuum or argon to protect the environment, ensuring that the grain size is controlled within the range of 0.5-2 microns, thereby obtaining excellent wear resistance (wear rate <0.05 mm ³ / N · m ). This low wear rate allows it to maintain dimensional stability in long-term use. For example, the mold can withstand more than one million stampings, while the seals and nozzles need to maintain a small leakage rate (<0.01 mL/min) and flow deviation (<1%). The geometrically optimized curvature radius (>0.5 mm) design effectively reduces stress concentration and prolongs the life of parts, while its impact resistance (impact energy>50 J) ensures reliability under dynamic loading. In addition, cemented carbide wear-resistant parts can be further improved in high temperature performance and oxidation resistance by adding trace elements (such as tantalum carbide TaC or niobium carbide NbC ) to adapt to more demanding industrial environments.
12.1.2 Characteristics of cemented carbide wear-resistant parts
The characteristics of cemented carbide wear-resistant parts are reflected in their unique microstructure and physical properties. High hardness (HV 1600-2200±30) makes it resistant to surface wear and is particularly suitable for machining high-hardness materials (such as hardened steel HRC 50-60 or titanium alloy HRC 30-35), while fracture toughness K ₁ c 10-20 MPa·m ¹ / ² ± 0.5 ensures the structural integrity of the parts under shock or vibration conditions. In addition, cemented carbide also has excellent corrosion resistance (durability >1000 hours in acidic or alkaline environments) and high temperature stability (operating temperature can reach 800°C±50°C), which makes it outstanding in the chemical, energy and metallurgical fields. Thermal conductivity (about 80-120 W/ m·K ) also helps to dissipate heat and reduce thermal damage during cutting or friction. The surface roughness (Ra 0.1-0.5 microns) after precision polishing further improves the contact performance and service life of the parts. These properties together constitute the competitive advantage of cemented carbide wear-resistant parts under high-intensity working conditions.
12.1.3 Performance balance of cemented carbide wear-resistant parts
The performance optimization of cemented carbide wear-resistant parts is inseparable from the coordination of hardness and toughness. The hardness range HV 1600-2200±30 provides excellent resistance to surface wear, and is particularly suitable for the processing of high-hardness workpieces (such as hardened steel HRC 50-60); at the same time, the fracture toughness K ₁ c 10-20 MPa·m ¹ / ² ± 0.5 ensures that the parts are not easy to crack when encountering mechanical shock or thermal stress. This balanced characteristic makes cemented carbide wear-resistant parts perform well in applications such as mold forming, sealing and leak prevention, and injection control. For example, the mold needs to withstand high-frequency impact (hundreds of times per minute), the seal needs to resist corrosive media (such as sulfuric acid or salt water), and the nozzle needs to precisely control fluid dynamics (flow deviation <1%). These requirements are achieved through fine regulation of materials and processes. In addition, through heat treatment (such as low-temperature tempering 500°C±20°C) or surface coating (such as TiN or CrN ), the hardness can be further enhanced (increase of 10%-20%) or the friction coefficient can be reduced (<0.3), thereby optimizing the performance in specific application scenarios.
12.1.4 Application of Cemented Carbide Wear-Resistant Parts
have shown extensive and diverse application value in the industrial field due to their high hardness (HV 1600-2500), excellent wear resistance (wear rate <0.05 mm³ / N · m ) and impact resistance (impact energy>50 J). The following systematically organizes and optimizes their applications according to application fields and functional logic, covering traditional manufacturing, emerging high-tech industries and usage scenarios in special environments.
(1) Metal processing and forming
Carbide mold
Widely used in metal stamping, plastic injection molding and powder metallurgy molds, it has high wear resistance and dimensional stability, with a typical life of more than 10 ⁶ times. Especially in the automotive manufacturing industry (such as engine blocks and transmission parts) and electronic component production (such as mobile phone housings and circuit board connectors), its high hardness (HV 1600-2200) ensures accuracy and durability under long-term high-frequency use, especially in smart manufacturing to support the precision molding of complex geometries.
Carbide cutting tools
It is used for high-speed cutting (such as turning, milling and drilling) in metal processing and wood processing. Due to its high hardness (HV 1800-2500) and resistance to high-temperature oxidation (heat resistance up to 900°C), it performs well in aerospace (such as titanium alloy parts) and automobile manufacturing (such as engine crankshafts). The cutting speed can reach 200-300 m/min and the service life can reach 200-300 hours.
Carbide extrusion die
For aluminum profiles and plastic extrusion, with a temperature resistance of up to 600°C, a hardness of HV 1700-2100, and a dimensional accuracy of ±0.01 mm, it is widely used in the construction industry (such as aluminum alloy doors and windows) and packaging material production to ensure efficient molding and surface quality.
(2) Fluid control and sealing
Carbide seals
Used in pumps, valves and compressors to prevent fluid or gas leakage, with a leakage rate of <0.01 mL/min. Its excellent corrosion resistance and low friction properties make it outstanding in the petrochemical industry (such as refining equipment and pipeline systems) and water treatment industry (such as sewage treatment pumps and filtration systems), especially when dealing with acidic or alkaline media, it extends the equipment maintenance cycle.
Carbide valve core and seat
Used for high-pressure valves in oil and gas and chemical equipment, with a pressure resistance of >50 MPa, excellent corrosion resistance (resistance to H₂S and CO₂ corrosion >2000 hours), and a leakage rate of <0.005 mL/min, ensuring reliable sealing performance in extreme environments.
Carbide Nozzle
Applied to sandblasting, spraying and 3D printing, with flow deviation of <1%, it performs well in aerospace (such as jet engine components), additive manufacturing (such as high-precision metal 3D printing), semiconductor manufacturing (such as chemical vapor deposition equipment) and energy industries (such as gas turbine nozzles). Its high wear resistance and precise fluid control capabilities significantly improve production efficiency and finished product quality.
(3) Mining and abrasive processing
Carbide Mining Drill Bits
It exhibits ultra-long service life (>100 hours) under extreme conditions such as deep mining. Its high hardness and impact resistance support efficient drilling. It is widely used in the coal, metal mining and oil drilling industries, reducing replacement frequency and operating costs.
Carbide grinding balls and grinding media
Used for mineral processing, ceramic production and coating grinding, with a ball diameter range of 5-50 mm, hardness HV 1600-2000, and wear rate <0.01%/hour, it significantly improves grinding efficiency and product uniformity, especially in the preparation of lithium battery materials and high-end ceramic production.
(4) Transmission and mechanical parts
Carbide Rollers
In the hot and cold rolling process of the steel industry, the wear-resistant layer thickness reaches 5-10 mm and the hardness HV 1500-2000, ensuring the surface quality of the rolled steel (Ra <0.8 micron) and the service life >5000 tons of steel rolled. Its stability under high load (pressure >200 MPa) and high temperature (600-1000°C) conditions makes it indispensable in heavy metallurgical equipment.
Carbide gears and transmission parts
Used in heavy machinery, wind power equipment and ship propulsion systems, the tooth surface hardness is HV 1800-2200, the fatigue strength is >1000 MPa, it reduces wear and noise, performs well under high torque (>500 Nm) conditions, and has a service life of up to 10 years.
Carbide bearing bushings
It provides low wear and high load support in heavy machinery and wind power generation equipment, has excellent wear resistance and anti-fatigue performance, and is widely used in high speed (>3000 RPM) and high load (>10 kN ) environments.
(5) Wire and precision manufacturing
Carbide Wire Drawing Dies
Applied to metal wire and cable manufacturing, with a hole diameter tolerance of ±0.001 mm and a surface roughness of Ra <0.1 micron, it is suitable for drawing copper wire, steel wire and optical fiber preforms, with a service life of >10 ⁴ drawing cycles, especially in the electronics and communications industries (such as 5G infrastructure).
(6) Medical and special industries
Cemented Carbide Medical Device Components
Such as orthopedic surgical saw blades and dental drills, with a diameter of 0.5-6 mm, a hardness of HV 1800-2200, biocompatibility in accordance with ISO 10993 standards, and a lifespan of >50 surgeries. In 2025, with the development of medical robot technology, its application in minimally invasive surgery and implant processing will increase.
(7) Emerging fields and future potential
With the advancement of industrial technology, carbide wear-resistant parts have shown broad prospects in electric vehicle battery production equipment (improving electrode material processing accuracy), robot joint components (enhancing motion durability) and space exploration equipment processing ( such as high-temperature resistant spacecraft components). In addition, its high wear resistance and stability have also become key support in the manufacture of quantum computing equipment and renewable energy equipment (such as hydrogen production equipment). In the future, combined with artificial intelligence optimization design and sustainable manufacturing technology, its application boundaries will be further expanded.
These applications benefit from the excellent performance of cemented carbide, and its performance in diverse industrial scenarios has promoted a comprehensive upgrade from traditional manufacturing to cutting-edge technology.
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