Welcome to the official website of Guangzhou Sanxin Metal Technology Co., Ltd.!
Spray coating processing SPRAY PROCESSING
Thermal Spraying Tungsten Carbide Powder
Tungsten carbide itself is extremely hard (with a Mohs hardness of about 9 and a Vickers hardness well above 1500 HV). However, pure tungsten carbide coatings are highly brittle and very difficult to spray. Therefore, the tungsten carbide powders used in thermal spraying are not pure WC; rather, they are composite powders made by combining WC particles with a metallic “binder phase” (typically cobalt Co, but sometimes nickel Ni, chromium Cr, or cobalt-chromium alloy CoCr).
Product Description
Thermal Spraying Tungsten Carbide Powder
I. Core Features: Why Choose Tungsten Carbide?
Tungsten carbide itself is extremely hard (Mohs hardness approximately... 9. The Vickers hardness is significantly higher than. 15 00 HV), but pure tungsten carbide coatings are highly brittle and extremely difficult to spray-coat. Therefore, The tungsten carbide powder used in thermal spraying is not pure. WC, rather, is a composite powder made by combining WC particles with a metallic “binding phase” (typically cobalt Co, but also nickel Ni, chromium Cr, or cobalt-chromium alloy CoCr). 。
This kind of The “metal-ceramic” composite structure combines the advantages of both materials:
* WC particles : Offers extremely high Hardness and Wear resistance 。
* Metal-bonded phase ( Co, Ni, etc. : Provide Resilience 、 Impact resistance and melt during the spraying process, thereby... WC particles are effectively “bonded” together to form a dense coating.
Core performance of thermal-sprayed tungsten carbide coatings:
1. Extremely high resistance to abrasive wear It has extremely high resistance to scratches and cuts caused by hard particles (such as sand, dust, and minerals).
2. Excellent friction and wear resistance It exhibits excellent wear resistance when in sliding or rolling contact with other components.
3. Good corrosion resistance (Depending on the binder phase): Cobalt-based tungsten carbide generally has moderate corrosion resistance, whereas nickel-based or cobalt-chromium-based tungsten carbide exhibits better corrosion resistance.
4. A balance between higher hardness and good toughness Thanks to the metallic bonding phase, the coating is not as brittle as pure ceramics.
5. Moderate high-temperature resistance : At about It maintains its performance below 500°C; however, above this temperature, the bonding phase will soften and WC will oxidize, leading to a decline in performance.
II. Common Types of Tungsten Carbide Composite Powders
According to The methods for combining WC particles with the binder phase are mainly divided into two types:
1. Sintered for Reunion ( Agglomerated and Sintered)
* Preparation process : To make fine WC powder and metal binder phase powder are mixed and agglomerated into spherical particles via a "granulation" process, after which they are sintered to achieve a certain level of strength.
* Features This is the most commonly used type and offers the best cost-performance ratio. It features well-balanced coating performance and is suitable for most wear-resistant applications.
- Encapsulated ( Clad or Cored)
* Preparation process : By single The WC particles serve as the core, and a metallic bonding phase is coated on their surface.
* Features The production process is more complex and the price is higher. Typically, this results in a more uniform microstructure and superior coating performance, especially in terms of toughness and density.
Examples of Common Grades ：
* WC-Co series : As WC-12Co (containing 12% cobalt), WC-17Co (containing 17% cobalt). The higher the cobalt content, the better the coating's toughness, but its hardness will slightly decrease. 。 WC-17Co is more impact-resistant than WC-12Co.
* WC-Ni series : As WC-12Ni. Used in applications requiring better corrosion resistance, replacing WC-Co (since nickel is more corrosion-resistant than cobalt).
* WC-CoCr series : As WC-10Co-4Cr. Has the best overall performance. It boasts both excellent wear resistance and outstanding corrosion resistance.
III. Major Thermal Spray Processes
The performance of tungsten carbide coatings is strongly dependent on the thermal spray process employed; coatings produced by different processes exhibit significant differences in microstructure and performance.
Process | Principle | Features | Applicable Tungsten Carbide Type |
Supersonic Flame Spraying (HVOF) | Fuel (such as kerosene and hydrogen) is burned with oxygen under high pressure, generating a supersonic flame jet that accelerates and heats the powder. | Gold standard The particle velocity is extremely high (supersonic), and the heating temperature is relatively low. Coating Extremely dense ， High bonding strength ， Low oxide content ， Fewer WC decompositions. This maximizes the retention of WC’s hardness and wear resistance. | All types It is coated with tungsten carbide. First-choice process 。 |
High-speed air-fuel spraying (HVAF) | With Similar to HVOF, but using air as the combustion-supporting gas, it features lower combustion temperatures while maintaining a still-high velocity. | Temperature ratio HVOF is lower, Almost completely avoid WC decarbonization and decomposition The coating performance can be comparable to It is comparable to, or even superior to, HVOF, and is particularly well-suited for thermally sensitive materials. | All types Especially suitable for applications sensitive to oxidation. |
Atmospheric Plasma Spraying (APS) | The powder is melted by ionizing an inert gas through an electric arc, creating a high-temperature plasma jet (reaching temperatures of tens of thousands of degrees). | The flame jet has a high temperature and a relatively low velocity. The high temperature may lead to... WC particles Decarbonization (Decompose into W₂C and carbon reduce the coating’s hardness and wear resistance. The coating is less dense than that produced by HVOF. | There are still applications, but... is rapidly being HVOF/HVAF replacement , used in occasions that do not require extremely high standards. |
Explosive spraying (Detonation Gun, D-Gun) | The shock wave generated by the explosion of a mixture of oxygen and fuel gas is used to accelerate and heat the powder. | The shock wave generated by the explosion of a mixture of oxygen and fuel gas is used to accelerate and heat the powder. | Can be used for high-performance tungsten carbide coatings, but is inferior to... HVOF adoption. |
IV. Main Uses and Application Fields
Thermal-sprayed tungsten carbide coatings are used in nearly all industrial sectors that require extreme wear resistance.
1. Aerospace industry
* Aircraft landing gear Actuator piston rods and shaft components that resist sand and stone corrosion and wear.
* Engine components : Provides wear-resistant sealing for compressor blades, turbine shafts, and other components.
2. Petroleum and Natural Gas Industry
* Drilling and Production Equipment Drill bits, drill pipe joints, stabilizers, and pump cylinder plungers—designed to withstand extreme wear and corrosion from downhole mud and sand.
* Valves and Fittings Ball valves, valve seats, and seals ensure tight sealing and long service life even in harsh media.
3. Steel and Paper Industries
* Roller Surface strengthening of hot-rolled and cold-rolled rolls significantly extends the roll replacement cycle.
* Paper drying cylinder Cylinder shaft head and wear-resistant ring to reduce gear wear.
* Continuous casting line Guide rollers and pinch rollers resist high-temperature oxidation and wear.
4. Transportation and Energy
* Car engine Piston rings and valve tappets—reduce friction and improve efficiency.
* Hydroelectric turbine Blades and guide vanes resist cavitation and erosion caused by muddy water flows.
5. Other general industrial applications
* Pump Industry Shafts, mechanical seal rings, and bushings for centrifugal pumps and screw pumps, used for conveying media containing abrasives (such as slurry pumps).
* Textile machinery Guide wire device and friction disc to reduce wear on synthetic filament fibers.
* Tools and Molds Repair and reinforce worn tools and dies.
Summary
Thermal Spraying Tungsten Carbide Powder It is achieved by hardening the... A high-performance material composed of WC particles combined with a tough metallic binder phase. HVOF/HVAF It is the first-choice process for spraying this type of material, capable of producing extremely dense, high-performance wear-resistant coatings. Its applications virtually cover all areas where... Wear resistance In fields with extreme requirements, this is one of the key technologies in modern industry for extending the service life of components and enhancing equipment reliability. Which one to choose? The choice of WC-based powders (such as Co, Ni, or CoCr binder phases) and the appropriate spraying process depend on the specific service conditions (type of wear, temperature, presence of corrosion, etc.).
Prev: Thermal Spraying Nickel-Chromium—Chromium Carbide Powder
Next: Introduction to Wear-Resistant Powder Materials for Thermal Spraying
Online Quotation
Related products
Spraying equipment SPRAY EQUIPMENT
Thermal Spraying Tungsten Carbide Powder
Tungsten carbide itself is extremely hard (with a Mohs hardness of about 9 and a Vickers hardness well above 1500 HV). However, pure tungsten carbide coatings are highly brittle and very difficult to spray. Therefore, the tungsten carbide powders used in thermal spraying are not pure WC; rather, they are composite powders made by combining WC particles with a metallic “binder phase” (typically cobalt Co, but sometimes nickel Ni, chromium Cr, or cobalt-chromium alloy CoCr).
Product Description
Thermal Spraying Tungsten Carbide Powder
I. Core Features: Why Choose Tungsten Carbide?
Tungsten carbide itself is extremely hard (Mohs hardness approximately... 9. The Vickers hardness is significantly higher than. 15 00 HV), but pure tungsten carbide coatings are highly brittle and extremely difficult to spray-coat. Therefore, The tungsten carbide powder used in thermal spraying is not pure. WC, rather, is a composite powder made by combining WC particles with a metallic “binding phase” (typically cobalt Co, but also nickel Ni, chromium Cr, or cobalt-chromium alloy CoCr). 。
This kind of The “metal-ceramic” composite structure combines the advantages of both materials:
* WC particles : Offers extremely high Hardness and Wear resistance 。
* Metal-bonded phase ( Co, Ni, etc. : Provide Resilience 、 Impact resistance and melt during the spraying process, thereby... WC particles are effectively “bonded” together to form a dense coating.
Core performance of thermal-sprayed tungsten carbide coatings:
1. Extremely high resistance to abrasive wear It has extremely high resistance to scratches and cuts caused by hard particles (such as sand, dust, and minerals).
2. Excellent friction and wear resistance It exhibits excellent wear resistance when in sliding or rolling contact with other components.
3. Good corrosion resistance (Depending on the binder phase): Cobalt-based tungsten carbide generally has moderate corrosion resistance, whereas nickel-based or cobalt-chromium-based tungsten carbide exhibits better corrosion resistance.
4. A balance between higher hardness and good toughness Thanks to the metallic bonding phase, the coating is not as brittle as pure ceramics.
5. Moderate high-temperature resistance : At about It maintains its performance below 500°C; however, above this temperature, the bonding phase will soften and WC will oxidize, leading to a decline in performance.
II. Common Types of Tungsten Carbide Composite Powders
According to The methods for combining WC particles with the binder phase are mainly divided into two types:
1. Sintered for Reunion ( Agglomerated and Sintered)
* Preparation process : To make fine WC powder and metal binder phase powder are mixed and agglomerated into spherical particles via a "granulation" process, after which they are sintered to achieve a certain level of strength.
* Features This is the most commonly used type and offers the best cost-performance ratio. It features well-balanced coating performance and is suitable for most wear-resistant applications.
- Encapsulated ( Clad or Cored)
* Preparation process : By single The WC particles serve as the core, and a metallic bonding phase is coated on their surface.
* Features The production process is more complex and the price is higher. Typically, this results in a more uniform microstructure and superior coating performance, especially in terms of toughness and density.
Examples of Common Grades ：
* WC-Co series : As WC-12Co (containing 12% cobalt), WC-17Co (containing 17% cobalt). The higher the cobalt content, the better the coating's toughness, but its hardness will slightly decrease. 。 WC-17Co is more impact-resistant than WC-12Co.
* WC-Ni series : As WC-12Ni. Used in applications requiring better corrosion resistance, replacing WC-Co (since nickel is more corrosion-resistant than cobalt).
* WC-CoCr series : As WC-10Co-4Cr. Has the best overall performance. It boasts both excellent wear resistance and outstanding corrosion resistance.
III. Major Thermal Spray Processes
The performance of tungsten carbide coatings is strongly dependent on the thermal spray process employed; coatings produced by different processes exhibit significant differences in microstructure and performance.
Process | Principle | Features | Applicable Tungsten Carbide Type |
Supersonic Flame Spraying (HVOF) | Fuel (such as kerosene and hydrogen) is burned with oxygen under high pressure, generating a supersonic flame jet that accelerates and heats the powder. | Gold standard The particle velocity is extremely high (supersonic), and the heating temperature is relatively low. Coating Extremely dense ， High bonding strength ， Low oxide content ， Fewer WC decompositions. This maximizes the retention of WC’s hardness and wear resistance. | All types It is coated with tungsten carbide. First-choice process 。 |
High-speed air-fuel spraying (HVAF) | With Similar to HVOF, but using air as the combustion-supporting gas, it features lower combustion temperatures while maintaining a still-high velocity. | Temperature ratio HVOF is lower, Almost completely avoid WC decarbonization and decomposition The coating performance can be comparable to It is comparable to, or even superior to, HVOF, and is particularly well-suited for thermally sensitive materials. | All types Especially suitable for applications sensitive to oxidation. |
Atmospheric Plasma Spraying (APS) | The powder is melted by ionizing an inert gas through an electric arc, creating a high-temperature plasma jet (reaching temperatures of tens of thousands of degrees). | The flame jet has a high temperature and a relatively low velocity. The high temperature may lead to... WC particles Decarbonization (Decompose into W₂C and carbon reduce the coating’s hardness and wear resistance. The coating is less dense than that produced by HVOF. | There are still applications, but... is rapidly being HVOF/HVAF replacement , used in occasions that do not require extremely high standards. |
Explosive spraying (Detonation Gun, D-Gun) | The shock wave generated by the explosion of a mixture of oxygen and fuel gas is used to accelerate and heat the powder. | The shock wave generated by the explosion of a mixture of oxygen and fuel gas is used to accelerate and heat the powder. | Can be used for high-performance tungsten carbide coatings, but is inferior to... HVOF adoption. |
IV. Main Uses and Application Fields
Thermal-sprayed tungsten carbide coatings are used in nearly all industrial sectors that require extreme wear resistance.
1. Aerospace industry
* Aircraft landing gear Actuator piston rods and shaft components that resist sand and stone corrosion and wear.
* Engine components : Provides wear-resistant sealing for compressor blades, turbine shafts, and other components.
2. Petroleum and Natural Gas Industry
* Drilling and Production Equipment Drill bits, drill pipe joints, stabilizers, and pump cylinder plungers—designed to withstand extreme wear and corrosion from downhole mud and sand.
* Valves and Fittings Ball valves, valve seats, and seals ensure tight sealing and long service life even in harsh media.
3. Steel and Paper Industries
* Roller Surface strengthening of hot-rolled and cold-rolled rolls significantly extends the roll replacement cycle.
* Paper drying cylinder Cylinder shaft head and wear-resistant ring to reduce gear wear.
* Continuous casting line Guide rollers and pinch rollers resist high-temperature oxidation and wear.
4. Transportation and Energy
* Car engine Piston rings and valve tappets—reduce friction and improve efficiency.
* Hydroelectric turbine Blades and guide vanes resist cavitation and erosion caused by muddy water flows.
5. Other general industrial applications
* Pump Industry Shafts, mechanical seal rings, and bushings for centrifugal pumps and screw pumps, used for conveying media containing abrasives (such as slurry pumps).
* Textile machinery Guide wire device and friction disc to reduce wear on synthetic filament fibers.
* Tools and Molds Repair and reinforce worn tools and dies.
Summary
Thermal Spraying Tungsten Carbide Powder It is achieved by hardening the... A high-performance material composed of WC particles combined with a tough metallic binder phase. HVOF/HVAF It is the first-choice process for spraying this type of material, capable of producing extremely dense, high-performance wear-resistant coatings. Its applications virtually cover all areas where... Wear resistance In fields with extreme requirements, this is one of the key technologies in modern industry for extending the service life of components and enhancing equipment reliability. Which one to choose? The choice of WC-based powders (such as Co, Ni, or CoCr binder phases) and the appropriate spraying process depend on the specific service conditions (type of wear, temperature, presence of corrosion, etc.).
Prev: Thermal Spraying Nickel-Chromium—Chromium Carbide Powder
Next: Introduction to Wear-Resistant Powder Materials for Thermal Spraying
Online Quotation
Exclusive customized hotline, 24 hours a day, 7 days a week:
Email:CarrieFeng07@outlook.com
Address: Building 8, Liandong U Valley Guangzhou Nansha International Enterprise Port, Nansha Free Trade Zone, Guangzhou City, Guangdong Province
Copyright © 2023 Guangzhou Sanxin Metal Technology Co., Ltd. All Rights Reserved
Powered by www.300.cn
