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Tungsten Carbide Bush- Widely Used Protective Component

The tungsten carbide bush also known as tungsten steel bushing, is a kind of component that protects the equipment, using the bushing, can effectively reduce the wear between the punch or bearing and the equipment and achieve a guiding role. The tungsten carbide bushing is mainly applied for stamping, with the features of wear resistance and impact resistance.

Excellent Characteristics Of Tungsten Carbide Bush

The tungsten carbide bushing has a series of excellent performances with high hardness, good concentricity, good perpendicularity, high wear resistance, high toughness, heat resistance and corrosion resistance. It has greatly improved the service life of the mold and has reduced the cost of molding manufacturers.

1. Advanced molding techniques can be adapted to produce a variety of shapes for carbide bush.

2. Small deformation with high accuracy.

3. High chemical stability.

4. High bending strength.

The Machining Method Of Tungsten Carbide Bush

The tungsten carbide bushing adopts CNC precision angles, inner hole grinder, precision surface grinding machine, precision internal and external round grinder, centerless grinder. The inner hole is grinded many times and polished into a mirror. The most suitable tool material for machining carbide bushing is a PCBN cutting tool.

The spray welding technology is adopted sometimes to increase the durability and service life of cemented carbide bush, which can reach HRC60 with better wear resistance. But the carbide bushing after welding needs turning machining to ensure the requirements for size and accuracy of the drawings.

Wide Applications Of Tungsten Carbide Bush

In the industrial fields, the application of cemented carbide bushing is very wide. The tungsten carbide sleeve is related to the role and purpose of its application environment in practical applications. In the valve application, the bushing should be mounted in the stem cover trap to reduce the valve leakage, for sealing. In the bearing application, the carbide bushing is adapted to reduce the wear between the bearing and the shaft seat, avoiding the clearance increasing between the shaft and the hole.

The tungsten carbide bushing is mainly used in the fields of stamping and stretching. The widely used tungsten carbide as tool material, includes a turning tool, a milling cutter, a planer, a drill bit, a boring cutter, etc, for cutting cast iron, non-ferrous metals, plastic, chemical fiber, graphite, glass, stone and ordinary steel, which can also be used for cutting materials which are difficult for machining, such as heat resistant steel, stainless steel, high manganese steel, tool steel.

In terms of stamping dies, the tungsten carbide bush is widely used because of high wear resistance, good finishing and no needing frequent replacement, thereby reaching the higher usage rate of equipment and personnel.

The carbide bushing has excellent chemical stability, which is widely applied in the industries of petrochemicals, submersible oil pumps, slurry pumps, water pumps, centrifugal pumps. With the increase in oil production, the shallow surface of the oil is reduced, In order to ensure oil usage, people have gradually developed to extract from the large deep well, but the difficulty of mining gradually increases and the mining components have high requirements for wear resistance, corrosion resistance or impact resistance. The tungsten carbide bush used as the wear-resistant component in the oil machinery, has high hardness, excellent wear resistance and a high degree of surface finishing, satisfying the use requirements for a daily and special performance in the oil machinery industry.

High performance tungsten carbide bush is a type of protective component with wide industrial applications, with high hardness, superior wear resistance, high strength, high toughness, heat resistance and corrosion resistance.

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Basic Introduction For Tungsten Carbide Roller

With the rapid development of the steel industry, in order to improve the output of steel and improve the utilization rate and productivity of the rolling mill, reducing the shutdown times of the rolling mill, adopting a tungsten carbide roller with long service life is an important method. For the rolling of wire, rod, tungsten carbide roller replacing conventional cast iron rolls and alloy steel rolls, has exhibited a lot of superiority, with the continuous development of roller manufacturing techniques and use technology, will continue to expand the applications of carbide roller rings and they will become more important in rolling machining with wider applications.

What Is The Tungsten Carbide Roller

The cemented carbide roller, also known as cemented carbide roller ring, refers to a roll made of tungsten carbide and cobalt through the powder metallurgical method. The tungsten carbide roll has two types of integral and is combined. It has superior performance, stable quality, high processing accuracy with excellent wear resistance and high impact resistance. Carbide roller is widely used for the rolling of the rod, wire rod, threaded steel and seamless steel pipe, which greatly improve the operation efficiency of the rolling mill.

High Performance Of Tungsten Carbide Roller

The carbide roll has a high hardness and its hardness value varies very small with temperature. The hardness value under 700°C is 4 times higher than the high-speed steel. The elastic modulus, the compressive strength, the bending strength, the thermal conductivity are also 1 times higher than the tool steel. Since the thermal conductivity of the cemented carbide roll is high, the heat dissipation effect is good, so that the surface of the roll is under high temperature for a short time and thus the high-temperature reaction time of harmful impurities in the cooling water and the roll is shorter. Therefore, the tungsten carbide rollers are more resistant to corrosion and cold and hot fatigue than tool steel rollers.

The performance of the tungsten carbide rollers is related to the content of the bond metal phase and the size of the tungsten carbide particles. The tungsten carbide is about 70% to 90% of the total composition and the average particle size is μm of 0.2 to 14. If the metal bond content is increased or increases the particle size of tungsten carbide, the hardness of the cemented carbide decreases and the toughness is improved. The bending strength of the tungsten carbide roller ring can reach 2200 MPa. The impact toughness can be reached (4 ~ 6) × 106 J / ㎡, and the HRA is 78 to 90.

The tungsten carbide roller can be divided into two types of integral and composite according to structural form. Integral tungsten carbide roller has been widely used in pre-precision rolling and finishing stand of high-speed wire rolling mills. The composite cemented carbide roller is composited through tungsten carbide and other materials. The composite carbide rollers are cast directly into the roller shaft, which is applied to a rolling mill with a heavy load.

Machining Method Of Tungsten Carbide Roller And Selection Rules Of Its Cutting Tools

Although the tungsten carbide material is better than other materials, it is difficult to machining due to extreme hardness and it is more widely used in the steel industry.

1.Concerning hardness

When machining the tungsten carbide rolls with a hardness smaller than HRA90, select HLCBN material or BNK30 material tool for a large amount of turning and the tool is not broken. When machining the carbide roller with a hardness of greater than HRA90, a CDW025 diamond tool is generally selected or grinding with a resin diamond grinding wheel. Generally, the higher the hardness is, the material is crisper, so it is more cautious for cutting of high hardness materials and the exact reserved finishing grinding allowance.

2.The machining allowance and processing methods

If the outer surface is machined and the allowance is large, generally adopts the HLCBN material or BNK30 material to be roughly processed, then grinding with a grinding wheel. For small machining allowance, the roller can be grinded directly with a grinding wheel or profiling processed by diamond tools. In general, cutting alternative grinding can improve machining efficiency and the cutting method is more conducive to improving the production lead time.

3.Passivating treatment

When machining a cemented carbide roller, passivating treatment is necessary to reduce or eliminate the sharpness value, for the purpose of flatness and smoothness with high durability. However, passivation treatment should not be too large, because the contact surface of the tool blade is large after passivation and the cutting resistance is also increased, which is easy to cause a crack, damaging the workpiece.

What Should Be Paid Attention To For The Production And Use Of Tungsten Carbide Roller

In recent years, the tungsten carbide rollers have gained more and more extensive applications in steel production with their excellent performance. However, there are still some issues in the production and use of cemented carbide rolls.

1. Develop a new type of roller shaft material. Conventional ductile iron roller shafts will be difficult to withstand greater rolling power and deliver a larger torque. So high-performance cemented carbide composite roll shaft materials must be developed.

2. During the manufacturing process of carbide rollers, the residual thermal stress caused by thermal expansion between the inner metal and outer cemented carbide must be minimized or eliminated. The carbide residual thermal stress is a key factor affecting the life of the roller. Therefore, the coefficient of thermal expansion difference between the selected inner metal and outer cemented carbide should be as small as possible, while considering eliminating the residual thermal stress of the carbide roller ring through heat treatment.

3. Due to the differences in the rolling force, rolling torque, heat transfer performance on different racks, the different racks should adopt different grades of carbide roller rings to ensure the reasonable match of the strength, hardness, and impact toughness.

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Prepararion Work And Heat Treatment For Tungsten Carbie Precision Part Machining

Tungsten carbide precision part machining technology is more and more widely adopted. It is essential and important in the precision part factory. The article mainly introduces useful knowledge about carbide precision part processing, such as four preparation work, heat treatment of the precision parts.

Four Preparations Must Be Done For Machining Tungsten Carbide Precision Part

There are three preparation stages when performing carbide precision parts machining.

1.Preparation stage

Before the precision machining of tungsten carbide, you need to analyze the pattern of processing parts, then determine the machining scheme, such as a process, selecting machine tool, processing cutting volume, tool, fixture, etc, and calculate the coordinate value of the tool path. It is worth spending some time for these necessary preparations, which can make your tungsten carbide parts machining are more smoothly completed.

2.Programming stage

After getting the process route and drawings, we need to write a CNC machining program language describing the processing based on the processing technology information, which can be identified by the system. Do a good job in programming, which isone of the key steps for precision parts machining.

3. Machining stage

When the program is executed, the machine tool system decodes, registers, and calculates the program, and sends a motion command to the machine servo mechanism, driving the moving parts of the machine tool automatically completing the precision parts processing.

The above three preparation stages are the indispensable steps before processing precision parts, which is a process from the drawing to the machining.

Points For Attention In Heat Treatment Of Tungsten Carbide Precision Part

In order to improve the performance of tungsten carbide precision parts, material cutting performance and eliminate the internal stress of the workpiece, some heat treatment procedures should be arranged in the machining process.

1. Preparatory heat treatment

The purpose of pre-heat treatment is to improve the cutting performance of the material, eliminate residual stress during blank manufacturing. Commonly used methods include annealing, normalizing.

2. Eliminate residual stress

Since the internal stress generated during the fabrication of the blank will cause the workpiece to deform and affect the machining quality, heat treatment must be arranged to eliminate residual stress. The best arrangement of the heat treatment for eliminating residual stress is after rough machining and before fine finishing. For parts that do not require high precision, annealing is usually performed before the blank enters the workshop to eliminate residual stress. For high-precision cemented carbide parts, such as precision screws, precision spindles, multiple heat treatments should be arranged to eliminate residual stress, and even ice-cold treatment is often used to stabilize size.

3.Final finish

The purpose of final processing is to increase the strength, surface hardness and wear resistance and is usually performed prior to grinding of tungsten carbide precision parts. Commonly used are quenching, carburizing, nitriding and carbonitride.

Therefore, in the tungsten carbide part machining, in order to improve the mechanical properties of the precision parts, heat treatment is essential, so that the processing quality conforms to the product requirements.

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What Is Tungsten Carbide Precision Part Machining Technology

Cutting is one of the common methods used in a tungsten carbide rod, carbide sheet and cemented carbide wire. For cutting the material of 1 mm or less, diamond ultra-thin cutting pieces are commonly used for machining.

The diamond resin matrix cutting piece, wherein the outer ring belt is a resin binding agent abrasive working layer, and the central portion is a high-strength metal, mostly for medium, large cutting slots and cutting.

During the tungsten carbide machining, the cutter tool itself must be higher than the hardness of the machined workpiece. At present, the cutting tool materials for turning tungsten carbide parts are mainly made of high-hardness high-resistant non-metallic adhesive CBN and the diamond PCD.

1. The tungsten carbide components which have a hardness of less than HRA90, select the BNK30 material CBN tool to carry out a large amount of turning and the tool is not broken. The carbide components which have a hardness greater than HRA90 generally select CDW025 Material PCD cutter tool or grinding with a diamond grinding wheel adopting a resin binding agent.

2.To process R3 groove or more of the carbide precision parts, for large machining allowance, generally adopts BNK30 CBN tool for roughing processing, then grinding with grinding wheels. For small processing margins, the grinding can be done directly with wheels , or adopting PCD tool for flush processing.

3.When the crescent groove rib of the tungsten carbide roller is processed, the CDW025 diamond carving milling cutter tool also known as rotary milling cutter is adopted.

For the milling process of carbide parts, according to customer needs, CVD diamond coating milling cutters and diamond insert milling cutter can be provided to perform tungsten carbide precision parts machining, which can replace electrolytic corrosion technology and electric spark process, improving production efficiency and product quality, such as a CVD diamond coating milling cutter to micro-milling the cemented carbide, and the surface roughness can reach 0.073 μm.

What Are The Factors Affecting The Machining Accuracy Of Tungsten Carbide Part

1. Machine tool error

The machine tool error refers to the manufacturing, installation errors and wears of machine tools. It mainly includes guide error of machine tool guide rail, machine tool spindle rotation error, transmission error.

2. Machining principle error

The machining principle error refers to an error generated by adopting the approximate blade profile or approximate transmission relationship for machining. The principle error often occurs in a thread, gear, complex surface machining.

3. Residual stress inside the workpiece

The residual stress is generated during the blank manufacturing, heat treatment process, cold strengthening and cutting processes.

4.Machining environment

The machining site often has many small chips. If there is a part locating surface or location of locating hole, which affects the processing accuracy of the parts, for high-precision processing, some small particles will affect the accuracy.

5.Manufacturing error and wear of the fixture

The error of the fixture is mainly referred to as the manufacturing error of positioning elements, tool guiding elements, an indexing mechanism. The fixture is assembled, with the relative dimensional error between the various components and worn on the working surface during use.

6.Manufacturing errors and wear of tools

The influence of tool error on machining accuracy varies according to the type of tools.

7.Thermal deformation of the processing system

During the machining process, due to the internal heat source, such as cutting heat, frictional heat or an external heat source such as temperature, heat radiation, the processing system is modified, thereby affecting the machining accuracy. In large workpieces and precision machining, the processing error caused by the thermal deformation of the processing system accounted for 40% -70% of the total processing error.

For more detailed information, please visit the article page of tungsten carbide precision part machining technology.

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Quickly Learning Of The Tungsten Carbide Plates

Tungsten carbide plates, also known as carbide strips or carbide sheets. They have shapes of rectangular and square. The main alloy ingredients of cemented carbide plates are WC and CO. They have extremely high hardness, wear resistance, high elastic modulus, good chemical stability, etc.

Wide Applications Of Tungsten Carbide Plates

The carbide plates have a high-pressure strength, high impact toughness, low expansion coefficient and thermal conductivity and electric conduction are similar to iron and its alloys. tungsten carbide plate is an excellent material for making high-temperature resistance parts, wear-resistant parts, anti-shielding parts, corrosion-resistant parts, suitable for making cast iron rolls and shaping cutter for high-nickel-red rolls, applied for silicon steel sheets, cold-rolled plates, production of wire drawing dies, wear-resistant parts, stamping parts, carbide automatic press mold cores, topping mode, such as top forging molds for screws, rivets, stamping molds. squeeze mold. punching mold.

Grade Properties And Applications

YG6

Fine grade alloy, with good wear resistance, used for processing blades, wear resistance parts

YG8

high bending strength, lower abrasion resistance than YG6A, suitable for manufacturing the form-cutter, wear-resistant consumable parts, etc.

YG15

Suitable for making stamping molds, wear-resistant parts, etc.

YG20

High bending strength, used for stamping dies.

YG20C

It is a fine grain carbide material, which has excellent wear resistance, high bending strength, anti-bonding ability, suitable for processing high-temperature alloys, stainless steel, high manganese steel and other materials.

Trustworthy Tungsten Carbide Plates Manufacturer - XYMJ

XYMJ, which has more than 20 years of experience in tungsten carbide products and tools such as tungsten carbide dies, carbide nozzles, cutting tools, mining tools, carbide wear parts, provide high-quality tungsten carbide plates at affordable prices. XYMJ is a professional carbide factory with advanced, highly effective equipment and high-precision grinding machines. All the products must be strictly inspected with ultrasonic. The sizes of XYMJ tungsten carbide plates can be customized as customers’ requirements.

Advantages of XYMJ tungsten carbide plates

1. The purity of the raw material is above 99.95% and the physical properties of the plates are stable.

2. Using spray drying technology, the material uses high purity nitrogen protection with full sealing, effectively reducing the oxygenation possibility in the preparation process of mixed material.

3.The plate density is uniformly adopting 300MPa pressures, effectively eliminating the generation of pressing defects, and the plate blank density is much more uniform.

4. Excellent density, strength and hardness are in line with the standard.

5. Adopting low-pressure sintering technology, so that the pores inside the plate can be effectively eliminated and the quality is much more stable.

6. Using deep cold treatment technology to improve the internal metallographic tissue of the plates or strips, and the internal stress can also be greatly reduced, effectively avoiding the appearance of cracks in the cutting process.

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What are tungsten carbide blades

The tungsten carbide blades and tips which are made of cemented carbide as the raw materials through fine finishing can be used as an industry blade, with excellent performance including high hardness, wear resistance, toughness and good corrosion resistance.

Advantages Of Tungsten Carbide Blades

1. The hardness is extremely high, up to Moh's hardness of 8.9-9.1, which is 10 times higher than the hardness of 18K gold. The high hardness makes carbide blades have good wear resistance, not easy to appear scratches and deformation.

2.It has high brightness like a mirror, with highly polished, fully glow in the color and light like the gemstone.

3.The corrosion resistance of tungsten carbide blades is good. It does not change color, no rust, and the luster can be maintained for a long time, which are the other metals don’t have.

What Should Be Paid Attention To Using Tungsten Carbide Blades

The characteristics of the carbide material determine the importance of the safe operation of cutting carbide blades.

1. Blade installation

Before the installation, please clear the dust, chips and other debris on the bearing mounting surface in advance, keep the bearing mounting surface and the tipper clean.

a.To carefully put the blade on the mounting surface of the bearing, rotate the tip machine shaft to automatically find the insertion of the blade center.

b. Install the crimping block on the tipper blade.

c. Load the hexagonal bolt, fasten the screws in the hex wrench to securely mount the blade on the bearing.

d.After the blade is installed, ensure no loose and no deflection.

2. Safety protection

After the blade is installed, the protective device must be equipped before starting the predicted machine and acts as a real protective effect.

3. Working speed

The working speed of the tipper is limited to below 4500 rpm/minute. It is strictly forbidden to exceed the limit speed.

4. Test machine

After the blade is installed, it is necessary to operate for 5 minutes and carefully observe the operation of the argument and cutting machine. It is absolutely not allowed to have obvious loose, vibrations and other abnormal sounds.

5.Push the circuit board uniformly

In the cutting process, please push the circuit board that needs to be cut at a uniform speed, avoiding being too rapidly to push the circuit board. When the circuit board has severely collided with the blade, it will cause blade damage.

6.Blade storage method

It is strictly forbidden to write on the blade with an electricity pen or other scratches to prevent damage to the blade body. The blade of the cutter is extremely sharp, but it is very crisp, In order to avoid accidental damage, ensuring the blade does not touch the human body or other metal hard objects.

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Useful Knowledge Shared For Tungsten Carbide Blades

Regardless of iron, aluminum or steel, the blades will cut them into the desired shapes when machining. The tungsten carbide blades are made of cemented carbide as the basic materials which is an alloy material hard made with hard compounds of refractory metals and bind metal through the powder metallurgy process.

Material Performance Of Tungsten Carbide Used As Blades

The tungsten carbide blade, also known as carbide tips, mainly adopts the overall hard alloy as the matrix and it is fine finished through various kinds of production processes. Carbide blades have extremely high hardness and high strength, excellent high wear resistance, high elastic modulus.

The tungsten carbide is distinguished according to the grain size, which can be divided into ordinary type, fine grain, sub-fine grain, ultra-fine grain, newly launched double-grain. According to the main chemical composition, cemented carbide can be classified into three types including tungsten cobalt (YG), titanium-tung-ste (YT), and adding rare carbonization (YW).

The tungsten carbide has a high hardness of 86 ~ 93HRA, equivalent to 69 ~ 81HRC, second only to diamond, good heat hardness of up to 900 ~ 1000 ° C, keeping 60 HRC, the high bending strength of MPA5100, good impact toughness and high corrosion resistance. The general alloy blade does not have these characteristics.

The Production Process Of Tungsten Carbide Blades

1. Ingredient

The main component of the cemented carbide blade is a different ratio of tungsten carbide and cobalt and the initial form of the raw material is the powder. The container is filled with a prepared raw material, which will be used to produce different powders.

2. Proportion

In the workshop, the dried raw materials are mixed with ethanol and water to form a grey pulp.

3. Open mold

After the grey pulp is dried, the sample is sent to the laboratory for quality detection. These powders are consisted of many particles having a diameter of 20 to 200 μm.

4. Press

These powders are contained in a bucket with the capacity of 100 kg, to be delivered to a punching machine for manufacturing a blade. Operation workers place the stamping dies into the machine tool. The pressure used for stamping each blade is as high as 12 tons. The machine tool will weigh the blade, and the operator will also perform observation and control. At this period, the blade is very fragile.

5.Sintering

For hardened, the blade after stamping needs to be heated. This work is done by the sintering furnace. Thousands of blades can be processed at a time. The pressed blade powder is heated to about 1,500° C for 13 hours. The shrinkage ratio of the sintering process is about 50%.

6. Waiting for grinding

Complete the required thickness of the quality inspection in the laboratory. Because the tungsten carbide is very hard, it is necessary to adopt industrial diamonds for grinding.

7. Grinding

When the blade reaches the required thickness, it is further grinded to obtain geometric shapes and sizes. Tolerance requirements are extremely stringent.

8. Coating

After the grinding is finished, the blade will be cleaned and sent to the coating. At this period, in order to avoid any oil grease or dust, the gloves must be worn for dealing with the blade and then sent into a coating furnace with lower pressure for different colors.

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Trustworthy Tungsten Carbide Mining Tool Manufacturer - XYMJ

Tungsten carbide mining tools, including buttons, tips, inserts, drilling bits, etc, with high performance, are widely used in oilfield drilling, snow removing, snowplow machine and other much more mining equipment, such as roller drill bits, DTH drill, geological drilling tools.

XYMJ, which is one of the most professional carbide mining tool manufacturers in China, provides carbide buttons, cemented carbide tips & inserts, with various types and specifications, customized service as the drawings also available.

The carbide buttons, inserts and tips are produced adopting 100% tungsten carbide, with stable product performance. The over-pressure sintering furnace is used for secondary sintering after ordinary sintering and the drill bit teeth do not fall, long service life guaranteed. They are manufactured with high precision centerless grinding machine, ensuring the dimensions are accurate and standard.

Advantages

1. Made by raw materials, with high wear resistance and durability.

2. Increase the compactness of the carbide inserts through the over-pressure sintering.

3. Superior quality is guaranteed, with a strict quality QC management team.

4. Custom service is provided as the customers’ requirements.

XYMJ will be one of the best choices for professional and trustworthy tungsten carbide mining tool manufacturer, superb product quality, the long service life of mining tools and competitive price guaranteed.

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Tungsten Carbide Mining Tool With High Working Performance

The tungsten carbide as the preferred mining tool material, includes carbide inserts, tungsten carbide buttons, cemented carbide tips, etc, widely used in the high-pressure DTH hammer drilling industry, suitable for petroleum drilling, quarrying, mining of various rocks and tunnels.

Tungsten carbide mining tools have their own unique working performance, with high hardness, good wear resistance, high impact toughness. The tungsten carbide inserts have high drilling speed, long service life, doing a favor to saving unproductive time, reducing labor and speeding up engineering speed, suitable for the mining of granite, the most robust sandstone and limestone, lean iron ore, which is a special component of the mining bits, also is used as a drilling bit accessory, applied in a heavy-duty rock drilling or deep hole drilling tool accessories.

Carbide buttons and tips are often used in mining drilling tools, mine machinery tools, oil drilling tools, road repairing tools to remove snow and road cleaning. With the high hardness of cemented carbide, They are widely used in the mining and quarrying, cutting process and can also be placed in heavy excavator drills.

The Grades And Applications Of Tungsten Carbide Mining Tool

YG4C

Mainly used as impact drill bits for cutting soft materials

YG6

Used as electric coal drill bits, coal mining bits, petroleum roller bits and scraper ball bits.

YG8

Suitable for core drill, coal mining & petroleum roller bits.

YG8C

Applied as the impact button bits of small and medium sizes, bearing bush of rotary exploration drill.

YG11C

Most of them are used for impact drills and inserts for cutting high-hardness materials in the rotary drilling bits.

YG13C

Applied as the inserts for the rotary percussive drilling bits to cut medium, high hardness materials.

YG15C

Suitable for cutting tools used in oil cone drills and the mining of soft, medium-hardness rocks.

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What Are The Main Differences Between Tungsten Carbide And HSS

HSS, which is the abbreviation of high-speed steel, is a standard material for metal cutting tools in the past time. When the tungsten carbide had been created, it was considered to be a direct replacement for HSS with good toughness, excellent wear resistance and extremely high hardness. Cemented carbide is usually compared to HSS, with similar applications and high hardness.

Performance

Tungsten carbide

The cemented carbide is a powder of a micron-magnitude metal carbide, which is hard to melt and has high hardness. The binder is made with cobalt, molybdenum, nickel, etc. It is sintered under high temperature and high pressure. Tungsten carbide has a higher high-temperature carbide content than high-speed steel. It has an HRC of 75-80 and excellent wear resistance.

Advantages

1. The red hardness of Tungsten carbide can reach 800-1000°C.

2.The cutting speed of cemented carbide is 4-7 times higher than the high-speed steel. Cutting efficiency is high.

3.The mold, measure tools and cutting tools made by tungsten carbide will have 20-150 times higher service life than alloy tool steel.

4.Cemented carbide can cut material with 50 HRC.

Disadvantages

It has low bend strength, poor impact toughness, high brittleness and low shock resistance.

HSS

HSS is high-carbon high alloy steel, which is a tool steel with high hardness, high wear resistance and high thermal resistance. In the quenching state, iron, chromium, partial tungsten and carbon in high speed steel form a extremely hard carbide, Improving the wear resistance of steel. The other partial tungsten is dissolved in the matrix, increasing the red hardness of steel, up to 650°C.

Advantages

1.Good strength, excellent toughness, sharp cutting edge.

2. Stable quality, generally adopted to make small tools with complex shapes.

Disadvantages

The hardness, service life and HRC are much lower than tungsten carbide. At a high temperature of 600°C or above 600°C, the hardness of HSS will decrease significantly, and it can’t be used.

Manufacturing Methods

Tungsten carbide

The manufacturing of cemented carbide is to mix tungsten carbide and cobalt in a certain proportion, pressurize into various shapes, and then semi-sintering. This sintering process is usually carried out in a vacuum furnace. It is placed in a vacuum oven to complete the sintering, and at this time, the temperature is approximately 1300°C and 1,500°C. The sintered tungsten carbide forming is to press the powder into a blank and then is heated to a certain degree in the sintering furnace. It needs to keep the temperature for a certain time and then cool down, thereby obtaining the desired carbide material.

HSS

The heat treatment process of HSS is more complicated than cemented carbide, which must be quenched and tempered. During the quenching, due to the poor thermal conductivity, it is generally divided into two stages. Preheat first at 800 ~ 850 °C, so as not to cause large thermal stress, then quickly heat to the quenching temperature 1190°C to 1290 °C which is distinguished when the different grades in the actual use. Then cool down by oil cooling, air cooling or gas-filled cooling.

Applications

Tungsten carbide

Wide applications of tungsten carbide, includes used as rock-drilling tools, mining tools, drilling tools, measuring tools, carbide wear parts, cylinder liner, precision bearings, nozzles, hardware molds such as wire drawing dies, bolt dies, nut dies, and various fastener dies, which have excellent performance, gradually replacing the previous steel mold.

HSS

HSS has good process performance with a good combination of strength and toughness, therefore mainly used to manufacture metal cutting tools with complex thin edges and good impact-resistant, high-temperature bearings and cold extrusion molds.

Material Ingredients

Tungsten carbide

The cemented carbide has a main component of a metal high hardness refractory carbide with WC, TiC micron powder, cobalt (CO) or nickel (Ni), molybdenum (MO) as the binder. It is the powder metallurgical product sintered in a vacuum furnace or hydrogen reduction furnace.

HSS

High speed steel is complex steel, with a carbon content generally between 0.70% and 1.65%, and 18.91% Tungsten content, a 5.47% Chloroprene rubber content, a 0.11% Manganese content, which is very close to the subsequent W18CR4V component.

For more information, please visit the article page of comparison between tungsten carbide and HSS.

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Material Properties Of Tungsten Carbide

Tungsten carbide is made of refractory metal hard compound (hard phase),which is generally a carbide, and metal binder (binding phase)obtained by powder metallurgy method,. As a hard alloy for cutting tools, the commonly used carbides are tungsten carbide (WC), titanium carbide (TiC), and tantalum carbide(TaC), niobium carbide (NbC), etc. The mostly used binder is Co. The strength of the tungsten carbide depends mainly on the content of cobalt.

Because of the high melting point,high hardness, good chemical stability, and good thermal stability that carbides in the cemented carbide have and the large amount of high-temperature carbon materials, the hardness and resistance Abrasiveness and heat resistance are higher than high speed steel.

The main component of the hard alloy hard phase is WC. WC has good wear resistance.although some carbides have the same hardness and WC, but do not have the comparable wear resistance. Besides,WC has a higher yield strength, so its resistance to plastic deformation is better. WC has good thermal conductivity, which is one of the most desirable properties for making tool materials. In addition. WC has a low coefficient of thermal expansion that is about 1/3 of steel.WC’s modulus of elasticity is three times that of steel, and its torsional modulus is twice that of steel. Therefore, the compressive strength of cemented carbide is also higher than that of steel. In addition, WC has good corrosion and oxidation resistance at room temperature, good electrical resistance, and high flexural strength. these excellent properties of WC have been passed to a hard alloy with its main component.

Compared with high speed steel, the hardness of cemented carbide is HRA89-94, which is much higher than the hardness of HSS (HRC63-70 or HRA83-86.6). The maximum cutting temperature allowed for tungsten carbide can reach 800-1000 °C or more, which could be much higher than HSS’s (550-650 ℃). The high temperature hardness of cemented carbide could be HRA82-87 at 540 °C,which is the same as the normal temperature hardness of high speed steel. The hardness at 760 ° C is HRA 77-85, and can maintained in HRA 73-76 at the environment of 1000-1100 ° C. Besides, Carbide’s wear resistance of cemented carbide is 16-20 times higher than that of the best HSS. Due to its high temperature hardness and wear resistance, cemented carbides have much higher cutting performance than high-speed steel and can increase tool durability by several tens of times. When machining ordinary structural steel, the cutting speed allowed is 4-10 times higher than that of high speed steel tools.

Tungsten carbide is widely used as tool materials, In the turning process, except for a small number of small diameter bores and some non-ferrous metal workpieces, almost all of them can be processed with carbide turning tools. In the drilling process, in addition to the existing carbide drills, carbide drills, deep hole drills, carbide injection drills and indexable carbide drills have also been successfully used to machine steel. In addition, carbide end mills have been widely used. Others such as reamer, end mill, small modulus gear hob, medium and large modulus gears for hard tooth surfaces, broaches and other tools use hard Alloys are also increasing. Although the proportion of cemented carbide in tool materials is lower than HSS and ranks second, its proportion of cutting chips is as high as 68%. According to reports, in some countries, more than 90% of turning tools and more than 55% of milling cutters are made of tungsten carbide, and this trend continues to grow.

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Why Choose cemented carbide as the material of mining tool

An excellent hard alloy for mining should have high strength, high hardness required for abrasion resistance and high toughness required for resistance to impact fracture. Because of the high hardness, wear resistance, and stable chemical properties, tungsten carbide mining tool is widely used.

1. Wear resistance of WC alloy

The shearer of the shearer is in direct contact with the coal seam during the working process. The abrasive wear characteristics of the shearer are closely related to the coal seam structure and hardness. The hardness of the coal is low, generally 100 to 420 HV, but the coal often contains different hardness. Impurities such as quartz and pyrite (900 to 1100 HV) have high hardness and have a great influence on the abrasive wear characteristics of picks.

In most of the operating examples, wear resistance is a basic function of material hardness. The higher the hardness, the higher the abrasive wear resistance. Pure WC is very hard and similar to diamond. In cemented carbide, WC particles form a strong skeleton, so WC cemented carbides exhibit very high hardness. In addition, WC belongs to the hexagonal crystal system and has anisotropy in hardness. The Vickers hardness of the bottom surface and the edge surface is 2 100 HV and 1 080 HV, respectively. In the coarse-grained cemented carbide, the proportion of WC grains on the plane is high, and thus the carbide containing the coarse-grained WC shows higher hardness. At the same time, at a high temperature of 1 000°C, coarse-grained WC hard alloys have higher hardness than ordinary hard alloys and show good red hardness.

In the coal cutting process, WC particles are exposed on the surface of the cemented carbide after cemented phases of the cemented carbide in the tool nose protected by the built-up edge have been squeezed away or are carried away by abrasive scraping. Bonded phase-supported WC particles are easily crushed, destroyed and released. Due to coarse WC grains, the cemented carbide has a strong holding force with respect to the WC, and the WC grains are difficult to pull out and exhibit excellent wear resistance.

2.Toughness of WC Alloy

When the cutter bit cuts the coal rock, the cutter head is subjected to high-stress stress, tensile stress and shear stress under the action of the impact load. When the stress exceeds the strength limit of the alloy, the alloy cutter head will be fragmented. Even if the generated stress does not reach the strength limit of the cemented carbide, the fatigue cracking of the cemented carbide will occur under the repeated action of the impact load, and the expansion of the fatigue crack may cause the tool head to fall off or chipping. At the same time, when cutting the coal seam, the shearer pick produces high temperature of 600-800°C on the cutting surface, and the cutting cutting coal seam is a periodic rotary motion. The temperature rise is alternating, and the temperature increases when the cutter head contacts the coal rock. , cool down when leaving the coal rock. Due to the constant change of the surface temperature, the dislocation density increases and concentrates, and the surface of the serpentine pattern appears.

The depth of cracks and the rate of propagation decrease with increasing carbide grain size, and the morphology, direction, and depth of cracks also vary with WC grain size. The cracks in fine-grained alloys are mostly straight and small and long; coarse-grained alloy cracks are irregular and short. The cracks mainly extend at the weak grain boundary. In the coarse-grained cemented carbide, if the micro-cracks bypass the coarse-grained WC grains, they are zigzag-shaped and must have energy that matches the fracture area; if they pass through When WC grains are expanded, they must have considerable fracture energy. As a result, the coarse-grained WC grains have enhanced deflection and bifurcation of cracks, which can prevent the further propagation of micro-cracks and increase the toughness of the cemented carbide. With the same content of cementitious phase, the coarse-grained alloy has a thicker bonding phase, which is beneficial to the plastic deformation of the bonding phase, inhibits the extension of cracks, and shows good toughness.

Studies on the strength and structure of WC-Co cemented carbide also show that there is a certain rule between the strength of tungsten carbide and the grain size of WC. When the cobalt content is constant, the strength of conventional low-cobalt alloys always increases as the grain size of WC in the cemented carbide becomes coarser, and the strength of the alloy with higher cobalt content peaks with WC grain coarsening.

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Why Choose Tungsten Carbide Nozzle

Tungsten carbide nozzle is made of precision machinery and cemented carbide material (superhard alloy). The bending resistance is 2300n / mm and the hardness is hra90 degree. When machining XYMJ cemented carbide nozzle, it provides precision grinding and surface treatment to achieve the hole roughness of ra0.1 and the roughness of both ends of R is Ra0.025. There is a scientific radius of curvature design at the two entrances. This design ensures the smooth passage of the thread. Due to the whole material processing, there is no elevation angle on the drilling hole, and the bending and blocking phenomenon has been improved compared with ruby nozzle. Carbide nozzle is made by hot pressing and sintering hot straight hole and hill hole. Because of its hardness, low density, excellent wear resistance and corrosion resistance, tungsten carbide nozzle has been widely used in sand blasting and shot peening equipment, which ensures that the product can be used in the best air and abrasive for a long time.

Advantages

Carbide nozzle and other nozzles: common nozzle materials include cast iron, ceramics, tungsten carbide, silicon carbide, boron carbide. Ceramic nozzles are only used in non aggressive light equipment and abrasive in explosion cabinets. Tungsten, silicon, and boron carbide are the most popular blasting applications due to their long service life. The following is a list of carbide nozzles and their comparison with other nozzles.

Approximate service life per hour

Nozzle material: steel shot / sand sand / alumina

Carbide nozzle 500-800 300-400 20-40

Alumina nozzle 20-40 10-30 1-4

SiC nozzle 500-800 300-400 50-100

Boron carbide nozzle 1500-2500 750-1500 200-1000

Types

The shape of nozzle hole of cemented carbide determines its air flow pattern. The nozzle generally has a straight hole or a limiting hole, a hill hole.

1. Straight hole : the straight hole nozzle forms a sealed air flow mode for on-site or internal air flow. This facilitates the realization of small tasks, such as cleaning parts, weforming, cleaning handrails, steps, plaques, or stone carvings and other materials.

2. Traditional long hill design

3. The orifice nozzle forms a sufficient airflow pattern, and the grinding speed can be increased up to 100% for a given pressure. The best choice of Venturi surface is to improve the productivity of the nozzle. Compared with the straight hole nozzle, the productivity of the long mound nozzle can be increased by 40% when the abrasive consumption is about 40%.

4. Double venturi : Double venturi and wide throat nozzle are the enhanced version of long venturi nozzle. The double dome style can be thought of as having two nozzles between a set of slits and holes to allow the incoming atmosphere to enter the downstream section. The outlet end is also wider than the traditional nozzle. These two modifications are made to increase the size of the airflow pattern and minimize abrasive loss at a speed.

5. Wide throat nozzle: wide throat nozzle is equipped with a large outlet and a large divergent outlet. When matched with the same size hose, they can increase productivity by 15% over a smaller throat nozzle. When wide throat nozzles also have large divergent holes, they can use a lower abrasive mode under higher pressure, and the yield can be as high as 60%.

For some lattice bridges, the back of the flange, the inside of the pipe type of shrink point, can effectively use angled nozzles. Many operators spend a lot of time and abrasive to wait for a bounce to complete the job. The use of angle nozzle as long as hair less time is always able to repair quickly, reducing the overall time.

Applications

The advantages of tungsten carbide nozzles include economy and longer service life when it is unavoidable to rough load and unload and media used to cut abrasives (glass beads, steel balls, steel sand, minerals or cinders). Traditionally, cemented carbide is the preferred material for tungsten carbide nozzle.

Carbide nozzle is widely used in surface treatment, sandblasting, spray painting, electronic, chemical process and other industries.

Cemented carbide nozzles are also used in different applications, such as for wire straightening, wire guides and other aspects.

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Trustworthy Tungsten Carbide Rod Manufacturer - XYMJ

XYMJ has more than 20 years of experience in researching and manufacturing tungsten carbide products such as carbide wire drawing dies, carbide plates & strips, tungsten carbide mining tips, carbide buttons, carbide circular blade and other much more customized tungsten carbide wear parts. XYMJ manufactures tungsten carbide rods with 100% virgin material, advanced sintering furnaces, high-precision grind machines, high stability and high performance guaranteed.

Advantages of XYMJ tungsten carbide rod

1. It adopts high-quality ultra-fine tungsten carbide and imported cobalt powder as raw materials.

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2. Standardized production technology using the advanced low-pressure sintering technique.

3. It has high strength and high hardness.

4. It has excellent red hardness, good wear resistance, high elastic modulus, high bending strength, superior chemical stability with high resistance of acid, alkali, high-temperature oxidation, superb impact resistance, low expansion coefficient.

5. It is manufactured with high-tech precision advanced equipment which is a low-pressure sintering furnace.

6. It is produced by a unique new process with the vacuum high temperature and high-pressure sintering. The pressure sintering is adopted at the finish time, which greatly reduces the porosity, improves the density and the mechanical properties of the product.

7. carbide rod has many material grades, which can adapt to different applications with complete specifications and precious carbide blank size which can reduce processing volume and improve productivity.

Tungsten carbide rod has the advantages of good HRC, high strength, excellent wear resistance, high chemical stability, etc, which is one of the preferred materials of the drill, end mills and milling cutters, widely used in various machining industries. XYMJ is one of the most trustworthy carbide rod manufacturers, with premium quality products, various types, high-precision equipment and competitive prices.

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What Is Tungsten Carbide Rod

Tungsten carbide rod, also called carbide round bar, is the preferred material for metal cutting tool manufacturing, widely used in the industries which has high requirements for wear-resistance, corrosion-resistance and high-temperature resistance. It has a lot of outstanding performance.

Tungsten carbide rod, as named as cemented carbide rod, is a high-hardness, high-strength and high-hardness material which has a major raw material of WC, with other metals and paste phases using powder metallurgical methods through low-pressure sintering.

Applications

Carbide rod is mainly suitable for drill, end mills and milling cutters, widely used for cutting, stamping and measuring tools, such as the micro-drill of the PCB industry, the electrode rod of the photoelectric communication, tungsten steel drill bit, drill handle, push rod, precision wear-resistance parts of the mechanical processing industry. It is the best material for the CNC milling cutter and machining cutter with hole.

carbide rod mainly is applied to the precision cutting of non-ferrous metals, YG6X and YG10X which are submicron grain grade, fiberglass reinforced plastic, titanium alloy, YG8X which is ultra-hard steel fine grain grade.

The Categories Of Tungsten Carbide Rod

Tungsten carbide rod with straight holes is available, including one, two, three holes, which has a spiral straight line with 30 degrees or 40 degrees or twisted. carbide rods also has the type of non-hole.

According to the structure, a tungsten carbide rod can be classified into a PCB tool, a solid tungsten carbide bar, a single straight-hole bar, double straight-hole bar, a two-spiral bar, three-spiral bar, and other types.

According to the molding process, carbide rods can be classified into two types of extrusion molding and compression molding. The difference is that the extrusion carbide rod and bars have a beautiful appearance, easy for grinding processing. The advantage of the molded bar is that the density is relatively uniform, but it is not conducive for grinding processing.

For more professional introduction, please visit the article page of tungsten carbide rod as the preferred material for metal cutting tool

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Industrial Applications Of Cemented Carbide

In most cases, cemented carbide products will have a good surface finish, allowing machining with super fast speed, much higher than high-speed steel and other tool steel, bearing higher temperature. Cemented carbide tool will have superior cutting performance with excellent wear resistance.

1. Cutting tool material

Cemented carbide adopted as the cutting tool material, is the widest application. Among the carbide tools, the tungsten cobalt carbide is suitable for the cutting of black metal, non-ferrous metals and processing of non-metallic materials, such as cast iron, cast brass, colloidal wood, etc. Cemented tungsten titanium cobalt is applied for steel and other black metals processing. In the same kind, there is more cobalt content, suitable for rough machining and less cobalt content is used for fine machining. Universal cemented carbide has a much longer service life than that of stainless steel which is difficult for processing.

2. Mould material

Cemented carbide is mainly used for cold wire drawing dies, cold punching dies, cold extrusion mode, cold heading dies and other cold stamping molds.

Under the wear-resistant working conditions which have a strong impact, the tungsten carbide cold heading mould is required to have a good impact toughness, fracture toughness, fatigue strength, bend intensity and excellent wear resistance. Usually, among grades of high cobalt and medium, crude granules, the YG15C is commonly adopted.

In general, the relationship between the carbide wear resistance and carbide toughness is contradictory. The increase in wear resistance will result in a decrease in toughness and the increase in toughness will inevitably lead to a decrease in wear resistance. Therefore, when choosing a cemented grade, it is necessary to meet specific usage requirements based on the processing objects and processing conditions.

If the selected grade is easy to occur early cracks, it is advisable to use a grade with high toughness. if the selected grades is easily damaged due to the early wear, it is appropriate to choose a grade with a higher hardness and better wear resistance. The following grades of YG15C, YG18C, YG20C, YL60, YG22C, YG25C have a gradual decrease in hardness and wear resistance and gradually improving toughness.

3. Measuring tools and wear parts

The cemented carbide is adopted in the wear surface inlay and parts of the measuring tools, precision bearing manufactured by grinding machine and the Cemented carbide wear parts such as guide bar, lathe center, valve seat.

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Industrial Applications Of Cemented Carbide

In most cases, cemented carbide products will have a good surface finish, allowing machining with super fast speed, much higher than high-speed steel and other tool steel, bearing higher temperature. Cemented carbide tool will have superior cutting performance with excellent wear resistance.

1. Cutting tool material

Cemented carbide adopted as the cutting tool material, is the widest application. Among the carbide tools, the tungsten cobalt carbide is suitable for the cutting of black metal, non-ferrous metals and processing of non-metallic materials, such as cast iron, cast brass, colloidal wood, etc. Cemented tungsten titanium cobalt is applied for steel and other black metals processing. In the same kind, there is more cobalt content, suitable for rough machining and less cobalt content is used for fine machining. Universal cemented carbide has a much longer service life than that of stainless steel which is difficult for processing.

2. Mould material

Cemented carbide is mainly used for cold wire drawing dies, cold punching dies, cold extrusion mode, cold heading dies and other cold stamping molds.

Under the wear-resistant working conditions which have a strong impact, the tungsten carbide cold heading mould is required to have a good impact toughness, fracture toughness, fatigue strength, bend intensity and excellent wear resistance. Usually, among grades of high cobalt and medium, crude granules, the YG15C is commonly adopted.

In general, the relationship between the carbide wear resistance and carbide toughness is contradictory. The increase in wear resistance will result in a decrease in toughness and the increase in toughness will inevitably lead to a decrease in wear resistance. Therefore, when choosing a cemented grade, it is necessary to meet specific usage requirements based on the processing objects and processing conditions.

If the selected grade is easy to occur early cracks, it is advisable to use a grade with high toughness. if the selected grades is easily damaged due to the early wear, it is appropriate to choose a grade with a higher hardness and better wear resistance. The following grades of YG15C, YG18C, YG20C, YL60, YG22C, YG25C have a gradual decrease in hardness and wear resistance and gradually improving toughness.

3. Measuring tools and wear parts

The cemented carbide is adopted in the wear surface inlay and parts of the measuring tools, precision bearing manufactured by grinding machine and the Cemented carbide wear parts such as guide bar, lathe center, valve seat.