Tungsten Carbide Balls Quality Control

Quality control of tungsten carbide balls is critical to ensuring their performance meets application requirements. This requires comprehensive management from raw materials and production processes to finished product testing, combining advanced testing methods with rigorous process monitoring to ensure stable product performance.

1. Raw Material Control

Powder Quality: Tungsten carbide balls are primarily composed of tungsten carbide (WC) and a binder (such as Co and Ni). The raw material purity, particle size, and chemical composition are strictly controlled to ensure that the carbide powder has a uniform particle size (typically micrometers) and is free of impurities.

Precise Formulation: The ratio of tungsten carbide to binder is adjusted based on the intended application (such as wear-resistant parts, sealing valves, etc.).

2. Production Process Control

The production process for tungsten carbide balls includes pulverizing, wet grinding, mixing, drying, screening, adding a molding agent, granulation, cold isostatic pressing, molding, and sintering. Each step requires strict monitoring:

Wet grinding and mixing: Ensure uniform powder mixing to avoid agglomeration or delamination, which could affect subsequent molding.

Cold isostatic pressing: Control the pressing pressure and time to ensure consistent density of the blank and prevent internal defects.

Sintering: Sintering is performed in a vacuum furnace or hydrogen reduction furnace. Temperature, time, and atmosphere must be precisely controlled to avoid over- or under-firing. Improper sintering can lead to porosity, cracks, and uneven properties.

Carbon content control: Adjusting the carbon atmosphere (such as methane or carbon monoxide content) during sintering controls the bonding of carbides and the binder to prevent insufficient carbon (formation of eta phase) or excessive carbon (precipitation of free carbon).

3. Inspection Methods

Dimensional Accuracy: High-precision measuring equipment (such as laser calipers) is used to check dimensional tolerances and roundness. Surface Quality: Surface defects such as cracks, pores, and inclusions are inspected using an optical microscope or scanning electron microscope (SEM).

Hardness and Strength: Hardness is tested using a Vickers or Rockwell hardness tester to ensure it meets application requirements. Compressive strength testing is also performed to verify impact resistance.

Internal Structure: Internal defects such as pores and cracks are inspected using X-ray or ultrasonic testing.

Chemical Composition Analysis: Carbon content, binder ratio, and impurity content are measured using a spectrometer to ensure compliance with formulation requirements.

4. Process Monitoring and Traceability

Quality Management System: We utilize ISO 9001 and other quality management systems to record raw materials, production parameters, and test data for each batch to ensure traceability.

Statistical Process Control (SPC): By monitoring key process parameters (such as sintering temperature and pressure), deviations are promptly identified and adjusted to reduce defective product rates.

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