Search Results (69)

High Velocity Oxy-Fuel (HVOF) thermal spraying enables the deposition of dense coatings with low porosity, high hardness, and good fracture resistance. Tungsten carbide–cobalt (WC-Co) coatings are widely used in industrial and aerospace applications due to their excellent wear resistance; however, improving crack resistance and coating–substrate adhesion remains a key challenge. In this study, WC-Co+Ni composite coatings were deposited on ductile cast iron, with emphasis on the role of Ni addition in controlling microstructure development under HVOF conditions. Microstructural characterization was performed using optical, scanning, and transmission electron microscopy (OM, SEM, TEM), while phase composition and chemical analysis were determined by X-ray diffraction (XRD) and energy-dispersive spectroscopy (EDS). The coatings exhibited a dense, low-porosity microstructure composed of fine WC and W₂C carbides embedded in a Co–Ni binder, with locally nanocrystalline regions. XRD analysis confirmed WC and W₂C as the dominant phases, with weak reflections corresponding to the η-phase (Co₆W₆C), indicating local decarburization. The addition of Ni increases the fraction of the transient liquid phase during particle flight, enhancing carbide dissolution and mass transport in the binder, which accelerates decarburization kinetics and promotes η-phase formation. Simultaneously, Ni modifies the binder into a more ductile Co–Ni matrix, reducing the detrimental effect of brittle η-phase on coating integrity. Mechanical and tribological testing (instrumented indentation and scratch testing) demonstrated improved crack resistance, wear resistance, and adhesion. The results show that Ni addition enables process-driven microstructural tailoring of HVOF-sprayed WC-Co coatings, leading to enhanced performance despite the presence of η-phase. Full article

Tungsten carbides are important materials for various application fields. Their unique combination of mechanical properties makes them a good choice for applications demanding high hardness and moderate fracture toughness, such as cutting tools, oil and gas, mining, or machining industries. The microstructure is composed of a hard phase embedded in a soft, ductile binder. Cobalt, which provides the best compatibility with the tungsten carbide phase, is the main binder. However, some issues have been addressed to cobalt during the last decades, including a classification as a critical raw material by the European Commission, a fluctuation of its price due to intense use in batteries, and health and ethical problems. Nickel-based binders are thus a good alternative to cobalt. Nevertheless, their processing requires a higher sintering temperature to achieve full density, which leads to abnormal grain growth and thus reduces mechanical properties. The proposed solution is to use a small amount of boron, which is added during the milling of the powders, to reduce the sintering temperature. After vacuum sintering, the results show that the sintering temperature can be decreased to reach full density. Mechanical properties show enhanced hardness with moderately decreased fracture toughness compared to the parts without boron additions (hardness around 1450 to 1515 HV₃₀ and fracture toughness around 10 to 12 MPa√m). Those results provide a good hardness-to-toughness ratio. Full article

WC–Co composites are widely applied in various industries due to their high hardness and wear resistance. The addition of zirconia further enhanced the composite, improving grain refinement and reducing the friction coefficient. Zirconia submicron particulate reinforcement strengthened the cobalt binder phase, significantly improving the wear resistance. Tribological tests were performed in ball-on-flat dry sliding mode, against an Al₂O₃ counter body. The specimen WC–6Co–10ZrO₂ exhibited a decrease in volumetric loss ΔV by 66% compared to 94WC–6Co composite, and the wear rates W_s showed a 50% decrease for 4 wt.% zirconia addition and up to 80% when 10 wt.% ZrO₂ was added. In tribological tests, a five times larger load, 100 N instead of 20 N, caused an increase in the wear rate 1.1, 1.3, and 1.9 times for WC–Co, WC–6Co–4ZrO₂, and WC–6Co–10ZrO₂ compositions, respectively. Abrasive and adhesive wear mechanisms were identified. Full article

This study investigates the corrosion behaviour of a WC–6Co cemented carbide (94 wt% WC, 6 wt% Co) in acidic (pH 2) and alkaline (pH 13) electrolytes used for industrial PVD coating removal. The removal of the coating was not investigated, since no coatings were applied or analysed in this study. The objective was exclusively to simulate the corrosion response of the exposed substrate after the coating had been removed during electrochemical stripping. Potentiodynamic polarisation measurements were performed from OCP −0.2 V to +3 V at a scan rate of 1 mV·s⁻¹, followed by surface characterisation using SEM/EDS and laser profilometry to identify corrosion mechanisms and quantify material degradation. In an acidic solution, corrosion was dominated by cobalt dissolution, followed by the formation of a W–O-rich corrosion-product layer, as indicated by increased tungsten and oxygen contents in SEM/EDS analyses. The layer became increasingly porous and mechanically unstable at higher potentials. Progressive thickening of the corrosion-product layer and subsequent breakdown resulted in significant material loss, including surface abrasion up to ~8 µm. In alkaline electrolytes, SEM/EDS analyses revealed a Co–O-rich surface layer, suggesting cobalt-containing hydroxide/oxide corrosion products. These results suggest that surface-layer formation on WC–Co does not necessarily provide reliable corrosion protection, as stability and morphology strongly depend on pH. These findings provide valuable guidance for the use of cemented carbides in electrochemical stripping processes for PVD coating removal. Full article

Tungsten carbide and cobalt cutting tools require low surface roughness to improve cutting performance by reducing the wear from machining friction. While this is achieved by conventional manufacturing processes (pressing and sintering, grinding), with additive manufacturing processes it is more difficult (layer height, printing strategy). Since less costly and more sustainable solutions (without lubricants) are being studied as alternatives to conventional processes, a complementary technology (laser ablation) is suggested for the additive manufacturing of green WC-10Co. In this study, material extrusion (MEX) was used to produce green WC-10Co 3D objects, followed by laser ablation (50 W ytterbium fiber laser, 800–1100 nm wavelength) on their surface. Different laser strategies and parameters (power, speed, frequency, distance between lines, number of passages) were tested to find the most suitable. Most combinations were excluded by initial visual inspection, while the best ones were measured with a contact and non-contact profilometer. Further analysis was made on the composition and microstructure (with techniques such as Raman spectroscopy, scanning electron microscope, x-ray diffraction, and hardness indentation) to study what the interaction with the laser changed on the surface. Results show that with a combination of 50 W laser power, 1000 mm/s laser speed, 2000 kHz laser frequency, 0.1 mm distance between lines and three laser passages, it was possible to achieve a surface roughness of 0.6 µm (Sa) for the sintered WC-10Co, produced by MEX. No η-phase and graphite were detected, as well as microporosity and fissures. Full article

The research conducted in this paper is a practical example of the Design of Experiments methodology. In accordance with the assumptions of the experimental design, the authors drew attention to the problem: how should the spark plasma sintering process be planned to obtain the maximum amount of information needed to optimise the consolidation of the WC-6Co composite at the lowest possible cost? The DOE methodology—a powerful technique for investigating new processes and gaining knowledge about existing ones in order to optimise them for high performance—was employed in the study. The aim of the research was to optimise the consolidation of the spark-plasma sintering process of the WC-6Co composite using the DoE (Design of Experiments) methodology. Four sintering factors were selected for the study: sintering temperature (factor A, 1300–1400 °C); heating rate (factor B, 100–300 °C/min); sintering time (factor C, 150–600 s); and pressure (factor D, 40–50 MPa). Each consolidation factor was designed to cover three levels. The L9 orthogonal array was used. It was found that sintering temperature and heating rate had the greatest impact on apparent density. To validate the statistical model, sintering tests were performed at a temperature of 1380 °C, a heating rate of 100 °C/min, a sintering time of 150 s and a pressing pressure of 45 MPa. Validation analysis of the statistical model demonstrated consistency with the experimental results. The WC-6Co composite achieved an apparent density of 14.85 g/cm³, corresponding to 97.42% of the theoretical density, with a hardness of 1809 HV30 and total porosity of 2.583%. X-ray diffraction studies revealed the presence of tungsten carbide and cobalt in the structure. Full article

This work explores the effect of nitrogen ion implantation on the wettability of the cemented tungsten carbide–cobalt (WC–Co) tool surface used for wood-based panel machining. Nitrogen ions with an energy of 50 keV and a fluence of 1 × 10¹⁷ and 5 × 10¹⁷ cm⁻² were implanted into the surface layer of commercially available WC–Co indexable knives using the implanter without a mass-separated ion beam. The wettability was characterized by a contact angle instrument. The implantation of nitrogen ions into WC–Co tools caused a statistically significant and practically useful decrease in the contact angle. This obtained effect was dependent on the fluence of the implanted ions, and it changed over time. This effect may also explain the transfer from the workpiece and the surface capture of carbon atoms in the secondary structure formed during the machining of wood materials on tools with ion implantation. On the other hand, the layer of carbon on the surface of the tool formed during machining explains the reduction in friction coefficient observed in experiments and the increase in tool life during cutting. Full article

Machining hard metals presents various challenges, especially with materials like WC-Co, known for their exceptional hardness and wear resistance, making them ideal for cutting tools. Among machining methods, Electrical Discharge Machining (EDM) stands out for its ability to machine hard materials with no mechanical damage, which is critical for machining fragile components. For form shape machining symmetrical parts like WC-Co bars, electrical discharge turning (EDT) could be applied. Despite its potential, limited research exists on deep form turning of hard metals like WC-Co using EDT. This study addresses that gap by comparing the final geometrical outcomes of two EDT setups: vertical and horizontal tool electrode configurations. Additionally, the impact of workpiece rotational speed on surface quality was examined. Results showed that the vertical tool electrode setup produced more accurate geometries and smoother surfaces. Furthermore, increasing the workpiece’s rotational speed improved flushing efficiency, resulting in reduced surface roughness and a cleaner machined surface. Full article

The increasing reliance on conventional coatings such as WC-Co raises serious environmental and health concerns due to the toxicity of cobalt and the ecological footprint of these materials. To address this challenge, the present study explores the development of eco-friendly multifunctional coatings via the Plasma Spray (PS) process, using titanium (Ti), silicon carbide (SiC), and tungsten carbide-cobalt (WC-Co) mixtures as alternative feedstocks. Steel substrates were coated under different deposition strategies (powder mixing, layer-by-layer) and current settings (800-900 A). The coatings were characterized by scanning electron microscopy (SEM/EDX), 3D profilometry, sliding wear testing, and potentiodynamic corrosion measurements. Results showed that Ti-WC (mix, 900 A) and Ti-SiC (layer, 900 A) coatings achieved the most favorable performance, combining excellent adhesion, uniform coverage, reduced porosity, and improved resistance to wear and corrosion compared to conventional Cr₂O₃ coatings. Notably, Ti-WC coatings provided surface roughness values comparable to Cr₂O₃, while significantly lowering the environmental impact. These findings demonstrate that PS-based Ti-WC and Ti-SiC systems can serve as sustainable and high-performance alternatives for protective applications in harsh environments, particularly in marine industries, supporting the transition toward coatings with reduced ecological footprint. Full article

The present contribution showcases the potential brake emission reduction with Cr₂O₃ (chromium oxide) and WC-CoCr (tungsten carbide–chromium–cobalt) rotor coatings, as realized in our joint public–private research consortium. Particulate matter (PM) emissions from automotive braking systems have been characterized using a pin-on-disc tribometer equipped with particle measurement devices: a CPC (Condensation Particle Counter), an APS (Aerodynamic Particle Sizer), an SMPS (Scanning Mobility Particle Sizer), and a PM_2.5 sampling unit. Brake pad samples made from the same low-steel friction material were tested against a grey flake cast iron disc and two types of custom coated discs: a Cr₂O₃-coated disc and a WC-CoCr-coated disc. The friction pairs were investigated at a constant contact pressure of 1.2 MPa while the sliding velocity varied during the test, starting with 25 sequences at 3.6 m/s, followed by 19 sequences at 6.1 m/s, and finishing with 6 sequences at 11.2 m/s. The test results show encouraging 64% to 84% reductions in particle number (PN) emissions between 4 nm and 3 µm and 84% to 95% reductions in mass emissions (PM_2.5) thanks to the respective coated discs. SEM-EDXS (Scanning Electron Microscopy and Energy Dispersive X-ray Spectroscopy) analyses show that the hardness and roughness of the discs, the chemical reactivity (oxidation), and the abrasiveness of the three friction pairs are parameters that might explain this reduction in emission. Full article

Dry reforming of methane (DRM) into synthesis gas (CO + H₂) is one of the most important chemical reactions for industrial hydrogen production. It also enables the synthesis of hydrocarbons (liquid fuels) and other valuable products, providing an effective route for utilizing greenhouse gases. However, a major challenge limiting the implementation and scale-up of DRM is the high cost of stable and active noble metal-based catalysts, or the rapid deactivation of nickel- and cobalt-based catalysts due to coking and sintering of the active metal particles. In this context, the present work demonstrates that combining a highly active and inexpensive component (Ni) with tungsten carbide produces a composite material exhibiting high catalytic activity and resistance to oxidation and coking during DRM. Tungsten carbide was synthesized using a vacuum-free electric arc method, and nickel was subsequently deposited in varying amounts (1–25 wt.%) using the deposition–precipitation method with NaOH (DP). The resulting catalysts were characterized by X-ray diffraction, temperature-programmed reduction and Raman spectroscopy. Their performance was evaluated under DRM conditions, at atmospheric pressure and 800 °C, using different CH₄:CO₂ ratios. The most effective oxidation/(re)carbonization cycle, ensuring catalyst stability during DRM by balancing the rates of carbon formation and removal from the catalyst surface, was achieved with a nickel content of 20 wt.% and a CH₄ to CO₂ ratio of 0.67 in the feed gas mixture. Full article

Cobalt-based alloys such as Stellite 6 are widely applied in demanding conditions because of their good resistance to wear, erosion, and corrosion, but further improvements in erosion resistance are still required. This work analyzes the effect of adding titanium and tungsten on the structure and properties of Stellite 6 coatings produced by laser cladding, aiming to enhance their erosion resistance. Penetrant tests confirmed that the additions did not reduce coating quality, and macroscopic observations showed that appropriate process parameters allowed for defect-free coatings with strong bonding to the substrate. Microstructural studies carried out by SEM/EDS (Scanning Electron Microscopy/ Energy Dispersive Spectroscopy) and XRD (X-ray Diffraction) revealed that the reference Stellite 6 coating consisted of a cobalt-based austenitic matrix with interdendritic chromium carbides, while Ti and W additions led to the in situ formation of primary and eutectic (Ti,W)C carbides. Transmission electron microscopy showed a gradient in tungsten concentration inside the primary carbides, with progressive tungsten dissolution into the TiC lattice. Although different powder compositions had only a moderate effect on hardness, erosion tests demonstrated that the coatings with Ti and W exhibited clearly improved resistance. In particular, the in situ carbides enhanced erosion resistance at 30° impingement angles, while also maintaining high resistance under 90° impact. These findings confirm that modifying Stellite 6 with Ti and W during laser cladding is an effective way to improve its durability in erosive conditions. Full article

This article presents the wear characteristics of the working surface of WC-Co (Tungsten Carbide–Cobalt) tungsten carbide tools obtained using the innovative U-FAST (Upgraded Field-Assisted Sintering Technology) method for particleboard machining. Three groups of tools with a similar chemical composition but differing WC (Tungsten Carbide) grain sizes were tested. Milling tests were carried out on a CNC (Computer Numerical Control) machine tool with the following cutting parameters: spindle rotation at 15,000 rpm, a feed rate of 0.25 mm per tooth, and a feed rate of 3.75. The experimental results show that tools with submicron WC grit sizes of 0.4 µm and 0.8 µm have the longest tool life. Wear of the cutting edges occurred through the removal of the cobalt bond between the tungsten carbide grains, leading to fracture and mechanical removal of the grains from the cutting edge surface. The similarities in the relative wear characteristics of blades with submicron tungsten carbide grain sizes suggest that micro-abrasion and bond phase extrusion may be the main wear mechanisms under the experimental conditions. Nanometric WC grain size significantly influences tool wear through chipping and cracking. Full article

This paper presents a combined approach to the synthesis of WC-(Fe, Ni) hard alloys obtained by mechanical activation and spark plasma sintering (SPS). The main attention at this stage of the work is paid to studying the evolution of the morphology and phase composition of WC-(Fe, Ni) powder mixtures during high-energy milling and their subsequent sintering by the SPS method. The study analyzed the effect of the mechanosynthesis time and the binder phase content on the change in the average particle size, the degree of defect formation, and the phase composition of the powders. It was found that an increase in the milling time to 240 min promotes the formation of the WC nanocrystalline structure and the accumulation of microdefects, which is accompanied by a decrease in the average particle size and an increase in the dislocation density. The X-ray phase analysis of the samples after SPS confirmed the preservation of the WC phase and the formation of the γ-(Fe, Ni) matrix without the formation of secondary carbide phases. The analysis of sample shrinkage showed three main stages: initial compaction, intense shrinkage, and structure stabilization. The obtained data demonstrate that optimization of the parameters of mechanical activation and SPS allow for effective control of the phase composition and morphology of WC-(Fe, Ni) powders, which opens up opportunities for their subsequent study in conditions of aggressive environments and radiation exposure. Full article

This study proposes a laser texturing method to optimize adhesion and minimize residual stresses in CVD diamond films deposited on tungsten carbide (WC-Co). WC-5.8 wt% Co substrates were textured with quadrangular pyramidal patterns (35 µm) using a 1064 nm nanosecond-pulsed laser, followed by chemical treatment (Murakami’s solution + aqua regia) to remove surface cobalt. Diamond films were grown via HFCVD and characterized by Raman spectroscopy, EDS, and Rockwell indentation. The results demonstrate that pyramidal texturing increased the surface area by a factor of 58, promoting effective mechanical interlocking and reducing compressive stresses to −1.4 GPa. Indentation tests revealed suppression of interfacial cracks, with propagation paths deflected toward textured regions. The pyramidal geometry exhibited superior cutting post-deposition cooling time for stress relief from 3 to 1 h. These findings highlight the potential of laser texturing for high-performance machining tool applications. Full article