Tungsten carbide screw coating

Wear-resistant coating for battery rolls

1. Roller pressing is the most commonly used compaction process for lithium-battery electrode sheets. Compared to other processing methods, roller pressing significantly alters the pore structure of the electrode sheets and also affects the distribution of conductive additives, thereby impacting the electrochemical performance of the battery. 2. Based on comparative analyses with multiple electrode-sheet rolling machines and in close alignment with the needs of battery manufacturers, our company has developed a high-precision, high-strength coating for battery electrode-sheet rollers. This coating specifically enables precise control over the shape of the electrode sheets, effectively addressing the issue of uneven thickness—where the center of the sheet becomes thicker while the edges remain thinner—caused by deflection and deformation of the rollers. We have accumulated extensive experience in coating application across materials, equipment, processes, and solutions, and we are now successfully replicating these proven success stories. We will guide you through the entire coating-manufacturing transition process, ensuring: rapid production start-up; a reliable, one-stop supply solution covering materials, equipment, and processes; coating trials conducted either at your site or at our technical center; and consistently high coating quality and efficiency.

Tungsten carbide spray coating for mixing equipment dispersing discs

1. The specialized isolation layer for lithium equipment and the tungsten carbide wear-resistant coating applied to dispersing discs are widely used in the lithium battery slurry industry. They are suitable for various types of lithium-ion equipment, including dispersing discs, helical shafts and screw mixers, wear-resistant components of pulverizers, tanks, cylinders, conical hoppers, powder handling machines, feeders, electrode manufacturing equipment, and other wear-resistant coatings. 2. The tungsten carbide coating achieves a hardness of HRC75 or higher—second only to diamond among ultra-hard, wear-resistant coatings. It effectively prevents metal ions from entering the powder, thereby avoiding metal contamination that could degrade powder quality. 3. Guangzhou Sanxin utilizes American Plazex supersonic spraying equipment and imports high-quality tungsten carbide materials. This tungsten carbide coating is particularly well-suited for applications involving particle abrasion. 4. During coating application, the workpiece temperature does not exceed 150 degrees Celsius, ensuring no deformation occurs on the workpiece. 5. The coating’s surface roughness is below R3.2, and its thickness can be precisely controlled between 0.10 and 0.35 mm. After pore-sealing treatment, the coating remains chemically inert and does not react with NMP. 6. Depending on the specific operating environment, users can select wear- and corrosion-resistant coatings tailored to their needs. 1. The specialized isolation layer for lithium equipment and the tungsten carbide wear-resistant coating applied to dispersing discs are widely used in the lithium battery slurry industry. They are suitable for various types of lithium-ion equipment, including dispersing discs, helical shafts and screw mixers, wear-resistant components of pulverizers, tanks, cylinders, conical hoppers, powder handling machines, feeders, electrode manufacturing equipment, and other wear-resistant coatings. 2. The tungsten carbide coating achieves a hardness of HRC75 or higher—second only to diamond among ultra-hard, wear-resistant coatings. It effectively prevents metal ions from entering the powder, thereby avoiding metal contamination that could degrade powder quality. 3. Guangzhou Sanxin utilizes American Plazex supersonic spraying equipment and imports high-quality tungsten carbide materials. This tungsten carbide coating is particularly well-suited for applications involving particle abrasion. 4. During coating application, the workpiece temperature does not exceed 150 degrees Celsius, ensuring no deformation occurs on the workpiece. 5. The coating’s surface roughness is below R3.2, and its thickness can be precisely controlled between 0.10 and 0.35 mm. After pore-sealing treatment, the coating remains chemically inert and does not react with NMP. 6. Depending on the specific operating environment, users can select wear- and corrosion-resistant coatings tailored to their needs.

Tungsten Carbide Spray Coating for Pipelines, Coating for Feed Tubes in Lithium-Ion Battery Equipment, Wear-Resistant Spray Coating for Powder Conveying Pipes

Tungsten carbide spray coating for pipelines, coating for feed pipes in lithium-ion battery equipment, and wear-resistant coating for powder material pipes. 1. Currently widely used in the lithium-battery slurry industry, this coating is suitable for various components in lithium-ion battery equipment, including dispersion disks, screw shafts, spiral mixers, wear-resistant parts of pulverizers, tanks, and cylinders.

Tungsten carbide wear-resistant coating applied to the rotors and sealing devices of internal mixers.

Guangzhou Sanxin utilizes the advanced U.S.-imported PRAXAIR JP8000 supersonic spraying equipment to apply wear- and corrosion-resistant coatings to tungsten carbide-sprayed rotors, mixing chambers, and sealing devices of internal mixers. Guangzhou Sanxin utilizes the advanced U.S.-imported PRAXAIR JP8000 supersonic spraying equipment to apply wear- and corrosion-resistant coatings to tungsten carbide-sprayed rotors, mixing chambers, and sealing devices of internal mixers.

Tungsten carbide coating for electrode roll strips

Tungsten Carbide Coating for Electrode Rollers The typical manufacturing process for lithium-ion battery electrodes involves mixing active materials, binders, and conductive agents to form a slurry, which is then coated onto both sides of copper or aluminum current collectors. After drying to remove the solvent, the electrode sheets are formed. The particle coating on these electrode sheets is subsequently compacted and densified through calendering, followed by cutting or slitting into individual strips. Calendering is the most commonly used compaction technique for lithium-battery electrodes. Compared to other compaction methods, calendering significantly alters the pore structure of the electrode sheets and also affects the distribution of conductive agents, thereby influencing the electrochemical performance of the battery. To achieve an optimized pore structure, it is crucial to have a thorough understanding of the calendering compaction process. Figure 1 illustrates the basic process of electrode calendering—Material- Equipment- Process- Solutions. We have accumulated extensive experience in coating applications and are now replicating these successful cases. We will guide you through the entire coating-manufacturing transition process, ensuring: rapid production start-up; a reliable supply solution that covers all aspects—from materials and equipment to processes; coating trials conducted either at your site or at our technical center; and consistently high coating quality and efficiency.

The Influence of Tungsten Carbide Spray Particle Size on Coating Microstructure and Properties

The Influence of Tungsten Carbide Spray Particle Size on Coating Microstructure and Performance The size of WC particles in the original powder directly affects the microstructure and performance of tungsten carbide coatings sprayed onto a substrate. Nanocrystalline tungsten carbide coatings prepared using nanoscale powders exhibit higher hardness and toughness, as well as superior wear resistance, compared to micron-sized tungsten carbide coatings made from conventional micrometer-scale powders. Recent studies have shown that tungsten carbide coatings prepared using micro-nano composite powders outperform those made from purely nanoscale powders. However, there are currently relatively few reports on this topic. Therefore, this paper systematically investigates the microstructure and performance of supersonic flame-sprayed nanoscale, micro-nano composite, and micron-sized tungsten carbide coatings, exploring the impact of the original powder’s WC particle size on coating microstructure and performance. 1 Experimental Setup 1.1 Preparation of Tungsten Carbide Coatings Three types of WC-CoCr powders—FN-WC, PN-WC, and M-WC—with nano-, nano-micron mixed, and micron-sized WC particles were used as spray powders. In the FN-WC powder, aggregated nanoscale WC particles form micron- or submicron-sized agglomerates, which are then bonded together by a binder, as shown in Figures 1(a) and 1(b). The average particle size of these agglomerates ranges from 18.85 to 37.56 μm, with a loose bulk density of 5.48 g/cm³. The morphology of the PN-WC powder is illustrated in Figures 1(c) and 1(d); its cross-sectional microstructure reveals some free nanoscale particles along with predominantly submicron- or micron-sized particles. The average particle size of the PN-WC powder is 23.33–44.79 μm, with a loose bulk density of 5.6 g/cm³. The morphology of the M-WC powder is shown in Figures 1(e) and 1(f); the WC particles in the powder end-face microstructure range from 0.5 to 3 μm in diameter, with an average particle size of 21–50 μm and a loose bulk density of 5.0 g/cm³. XRD diffraction comparisons (Figure 2) and analysis results (Table 1) indicate that the WC particle size in the FN-WC powder is slightly smaller, followed by the PN-WC powder, while the M-WC powder has slightly larger WC particles. Table 1: Half-Width at Half-Maximum of Main WC Peaks Powder FWHM/(°) FN-WC 0.194 PN-WC 0.157 M-WC 0.148 The substrate used was 0Cr13Ni5Mo martensitic stainless steel. Before spraying, the substrate surface was cleaned and sandblasted. The spraying equipment was an HVOF system manufactured by SulerMecto in the United States. Propane was used as the fuel gas, high-pressure oxygen as the oxidizer, and nitrogen as the powder feed gas during spraying. The spraying process parameters are listed in Table 2. Table 2: Spraying Parameters Parameters Values Pressure (O₂)/MPa 1.0 Flow rate (O₂)/(L·min⁻¹) 240 Pressure (C₃H₈)/MPa 0.6 Flow rate (C₃H₈)/(L·min⁻¹) 68 Spray distance/mm 200 1.2 Microstructural and Mechanical Property Testing The microstructure of the coatings was analyzed using a FeiQuata400HV scanning electron microscope. Coating porosity was determined according to JB/T75059-1994. The bond strength of the coatings was tested using the paired specimen tensile test method specified in GB/T8642-2002. The bond strength tests were conducted on a CSS-44300 electronic testing machine at a loading rate not exceeding (1000 ± 100) N/s. The microhardness of the coatings was measured using an HDX-1000TMC/LCD microhardness tester under a load of 300 g for 15 seconds; nine points were tested per sample, and the average microhardness value of each coating was calculated. 1.3 Abrasive Wear Testing The abrasive wear tests were performed using a particle erosion wear testing machine similar in structure to the ACT-JP testing machine from Japan. The erosion test parameters were as follows: erosion distance 100 mm, nozzle inner diameter 3.6–4.0 mm, nozzle length 22 mm, abrasive material brown corundum with a particle size of 149 μm (100 mesh), compressed air pressure 0.3 MPa, and erosion angles of 15° and 90°. 2 Results and Discussion 2.1 Microstructure of the Coatings Figure 3 shows the SEM images of the cross-sections of the sprayed coatings. The porosity of the three coatings was statistically analyzed at 5000x magnification. The results show that the porosities of the FN-WC, PN-WC, and M-WC coatings were 2.1%, 2.0%, and 2.3%, respectively, indicating comparable porosity levels among the coatings. At higher magnifications, most of the WC particles in the FN-WC coating had diameters less than 100 nm, as shown in Figure 3(a2). Additionally, some flat particle boundaries showed no presence of nanoscale WC particles, as seen in the bright white metallic regions in Figure 3(a2). These regions likely resulted from partial melting of the nanoparticles in the supersonic flame jet, causing the small nanoscale WC particles to decompose at high temperatures. In the PN-WC coating, most of the WC particles had diameters greater than 500 nm, even reaching around 2 μm; however, some nanoscale particles were also present in the coating, as shown in Figure 3(b2). In the M-WC coating, the WC particles were micron-sized, and large WC particles broke during the spraying process, retaining their fractured morphology within the coating. The metal bonding phase between the fragmented tungsten carbide particles was insufficient, as shown in Figure 3(c2). 2.2 Phase Structure of the Coatings Figure 4 shows the XRD analysis results for the FN-WC, PN-WC, and M-WC coatings. After processing, the FN-WC coating exhibited a slightly higher relative peak intensity for the W₂C phase, indicating a higher degree of decomposition during spraying. This result is consistent with the microstructural analysis. Nanoscale tungsten carbide particles tend to decompose easily in the supersonic flame jet; when most of the WC particles in the powder exist as nanoparticles, their decomposition becomes more severe. In the PN-WC and M-WC coatings, most of the WC particles were micron- or submicron-sized and did not easily decompose, resulting in only minor traces of the W₂C phase observed in the XRD patterns. 2.3 Microhardness of the Coatings Coating hardness refers to the material's ability to resist deformation or fracture within a small volume on the surface, and its magnitude significantly influences the coating's wear resistance and erosion resistance. Figure 5 shows the microhardness test results for the three tungsten carbide coatings. The Vickers hardness values of the PN-WC and FN-WC coatings were 1241 HV0.3 and 1254 HV0.3, respectively, slightly higher than the M-WC coating’s hardness of 1229 HV0.3. The hardness of the PN-WC coating was more concentrated. Combined with the microstructural photographs of the three coatings shown in Figure 3, it can be seen that the FN-WC coating contains pure metal areas resulting from the decomposition of WC particles, whereas the M-WC coating has many fragmented WC particles. The uneven microstructures of these two coatings led to dispersed hardness values, while the PN-WC coating had uniformly distributed micron-nano WC particles, resulting in a more concentrated distribution of hardness values. 2.4 Bond Strength of the Coatings Table 3 shows the bond strength of the coatings. The average bond strength of the PN-WC coating was over 73.5 MPa, and the primary fracture during the tensile test occurred within the adhesive layer. The average bond strength of the M-WC coating was comparable to that of the PN-WC coating, and both of these coatings had slightly higher bond strengths than the FN-WC coating. This may be related to oxidation and WC particle decomposition phenomena occurring in the FN-WC all-nanoscale coating during the supersonic flame jet. In the FN-WC all-nanoscale coating, samples 3–5 all fractured within the coating. Table 3: Bond Strength of the Coatings Coating Bonding Strength/MPa Mean Value/MPa Fracture Position 1 2 3 4 5 FN-WC 72.3 74.8 62.6 70.4 63.2 68.7 Coating + Glue PN-WC 70.7 75.8 72.0 76.9 72.3 73.5 Glue M-WC 73.2 69.4 77.2 76.3 68.6 72.9 Glue 2.5 Erosion Resistance Performance The erosion tests were conducted by subjecting the coatings to abrasive particles corresponding to 100 g every 15 seconds, weighing the coatings after each test cycle. After the erosion tests, the cumulative mass loss due to erosion was calculated and converted into volumetric loss caused by coating erosion, using this volumetric loss as a criterion for evaluating erosion resistance. A linear fit was applied to the cumulative volumetric loss data, and the reciprocal of the slope of the fitted line was defined as the erosion resistance coefficient Re. Under the same test conditions, a higher Re value indicates better erosion resistance of the coated material. The erosion resistance results for the FN-WC, PN-WC, and M-WC coatings at a small angle (15°) are shown in Figure 6. Although the FN-WC coating used all-nanoscale WC particles, its erosion resistance did not improve significantly. On the contrary, the PN-WC coating, prepared using a mixture of nano- and micron-sized WC particles, showed a significant increase in erosion resistance. Compared to the M-WC coating, the PN-WC coating prepared with a nano-micron mixed WC particle composition demonstrated markedly improved erosion resistance, with an erosion resistance approximately 1.5 times that of traditional coatings and 2.3 times that of the 0Cr13Ni5Mo substrate. The hard WC phase in the coating is bonded by the CoCr alloy matrix; under real turbine operating conditions—specifically, at small-angle erosion—the metal matrix exhibits poorer wear resistance compared to the hard phase. Figure 6: Volumetric Loss of Coating Erosion at 15° Angle The PN-WC coating contains both large and small WC particles, evenly distributed within the CoCr alloy matrix, as shown in Figures 3(b1) and 3(b2). When abrasive particles erode the coating at a small angle, the metal matrix is easily worn away, exposing the large hard particle phase. As the erosion continues, the CoCr alloy matrix surrounding the large particles is gradually removed, leading to the detachment of these large particles. However, since the PN-WC coating contains small WC particles distributed within the metal bonding phase surrounding the large particles, these small particles can resist the erosion of the abrasive particles, mitigating the erosion of the metal bonding phase and delaying the detachment of the large WC particles. Thus, the PN-WC coating demonstrates superior erosion resistance. The decomposition of WC particles in the FN-WC coating is the main reason for its reduced erosion resistance. In the M-WC coating, the insufficient metal bonding phase between the fragmented small tungsten carbide particles negatively impacts the coating’s erosion resistance. Figure 7 shows the volumetric loss of erosion for the FN-WC, PN-WC, and M-WC coatings at a 90° angle.As can be seen, the erosion volume loss trends of the three coatings are quite similar. The erosion resistance Re of the PN-WC and FN-WC coatings are 4.70×10⁴ g/cm³ and 4.68×10⁴ g/cm³, respectively, slightly higher than that of the M-WC coating. Under a 90° impingement angle, the erosion volume loss of all three coatings is significantly greater than that of the substrate. The study indicates that metallic materials exhibit better erosion resistance than WC coatings at a 90° impingement angle. Figure 8 shows a comparison of the erosion wear morphologies of the FN-WC, PN-WC, and M-WC coatings. The erosion wear marks on all three coatings under a 90° impingement angle are more pronounced than those observed at a 15° impingement angle. The furrow-like erosion wear marks appear coarser, confirming that the volume loss during erosion at a 90° impingement angle is more severe than at a 15° angle. At a 15° impingement angle, the erosion furrow marks on the surface of the PN-WC coating are less distinct compared to those on the FN-WC and M-WC coatings; only a few shallow furrows can be observed. Combined with the erosion resistance of the three coatings at a 15° impingement angle, the PN-WC coating, owing to its superior erosion resistance, exhibits shallower and narrower furrows on its surface. In contrast, the FN-WC and M-WC coatings have lower erosion resistance, resulting in more prominent furrow marks. Conclusion: (1) Tungsten carbide coatings with three different WC particle sizes were prepared using the HVOF process. The FN-WC, PN-WC, and M-WC coatings have comparable porosity but differ in their phase structures. The FN-WC coating shows severe decomposition of tungsten carbide, whereas the PN-WC and M-WC coatings exhibit only slight decomposition of tungsten carbide particles. (2) The PN-WC coating has a more uniform microstructure, with minimal decomposition of the WC phase, a more concentrated hardness distribution, and slightly higher bonding strength, giving it excellent overall performance. It demonstrates superior erosion resistance at a 15° impingement angle and holds great potential for application in the field of anti-abrasive damage control for hydraulic turbine flow components. (3) The size of tungsten carbide particles is an important factor influencing coating performance; by selecting powders with appropriately sized tungsten carbide particles, high-performance coatings can be produced. We have accumulated extensive experience in material, equipment, process, and solution development for coating applications, and we are currently replicating these successful cases. We will guide you through the entire coating manufacturing transformation process, ensuring: rapid production start-up; a reliable supply solution covering materials, equipment, and processes; coating trials conducted either on-site at your facility or at our technical center; and consistently high coating quality and efficiency. Start collaborating with us today and reap success tomorrow!

Spraying tungsten carbide onto irregular-shaped pipelines for new energy equipment.

1. Tungsten carbide spraying for special-shaped pipes is now widely used in the lithium-battery slurry industry. It is suitable for various components in lithium-battery equipment, including dispersion disks, screw shafts and spiral mixers, wear-resistant parts of pulverizers, tanks, cylindrical bodies, conical hoppers, powder-handling machines, feeders, electrode manufacturing equipment, and wear-resistant coatings. 2. The tungsten carbide coating achieves a hardness of HRC75 or higher—second only to diamond—and boasts exceptional wear resistance. It effectively prevents metal ions from entering the powder, thereby avoiding contamination of the powder by metallic material wear. 3. Guangzhou Sanxin uses American Plasmax supersonic spraying equipment and imports tungsten carbide materials. Tungsten carbide coatings are particularly well-suited for applications involving particle abrasion. 4. During coating application, the workpiece temperature does not exceed 150 degrees Celsius, ensuring no deformation occurs in the workpiece. 5. The coating surface roughness is around R3.2, and the coating thickness can be precisely controlled between 0.10 and 0.35 mm. After sealing treatment, the coating does not react with NMP. 6. Depending on the specific operating environment, you can choose wear-resistant and corrosion-resistant coatings.

Screw wear-resistant coating—sprayed tungsten carbide

Screw for Plastics Machinery—Thermal Spraying and Coating Protection Area: The portion of the screw where material is pushed forward. Operating Condition: Material wear. Solution: Supersonic Thermal Spraying Method. Coating Material: WC/Co. Enhancement Effect: Extends service life by 1–2 times compared to conventional heat treatment. Processing Technology: In response to the specific requirements of various plastic products, most advanced engineering plastics currently in use contain additives such as flame retardants, glass fibers, calcium carbonate, and modifiers, which accelerate corrosion, wear, and shorten the service life of the barrel and screw. This process ensures that the sprayed alloy layer remains firmly bonded, free from cracks and porosity, and strictly controls issues such as workpiece deformation. Technical Specifications: Application: Extruders, Plastic Extruders, Extrusion Machinery. Screw Diameter: Φ15–Φ360. Length-to-Diameter Ratio: L/D = 15–45. Overall Hardness: HRC 58°–68°. Nitriding Depth: 0.4 mm–0.7 mm. Straightness: 0.015 mm–1000 mm. Screw Types: Gradual Transition Type, Step-Type, Wave-Type, Barrier-Type, Double-Barrier Type, Tapered Type, Splitter Type, Separator Type, Venting Type, Pin-Type, Hybrid Type, Double-Head, Triple-Head, Multi-Head, Granulation Type, etc. Applicable Materials: Common plastics, PA, PP, PC, PE, ABS, AS, PS, PVC, PMMA, LCP, PBT, PET, PPC, PPS, PAR, PO, magnetic powders, ceramic powders, aluminum-magnesium powders, iron powders, bakelite powders, and other engineering plastics.

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