Tungsten Carbide Rod Binder

Tungsten carbide rod is made up of two parts. One is the tungsten hardening phase which makes tungsten carbide rod be high wear resistance and high strength. The other part is the tungsten carbide rod binder like cobalt or nickel.

In 1923, Schroter from German add 10%-20% cobalt into cemented carbide as binder, invented the new alloy of cemented carbide and cobalt, and hardness is approximately the same as diamond. This is the first artificially synthesized tungsten carbide in the world. Tungsten carbide rod made by this method has high wear resistance and high strength and toughness.

Cobalt is by far the most widely used binder metal or "cement" in tungsten carbide rod because it most effectively wets tungsten carbide grains during liquid phase sintering. For this reason cobalt is believed to be superior to other binder metals in terms of eliminating residual porosity and achieving high strength and toughness values in sintered products.


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Tungsten Carbide Rod Producing Countries

About 50 countries manufacture tungsten carbide rod in the world and the total output can reach to 27000t-28000t. The main producing countries are America, Russia, Sweden, China, German, Japan, England and France. The tungsten carbide rod market has reached the saturated condition so the competition is really fierce. China started to make tungsten carbide rod in the end of 1950s. After a long time research, the technique and output improve a lot in the 1960s-1970s. In 1970s, the tungsten carbide rod producing capability reached to 6000t, the total output reached to5000t which is second only to Russia and America, ranked the third place in the world.

About 600-700 enterprises produce tungsten carbide rod in the world. Among which the most competitive ones are Sandvik in Sweden and Kennametal in America. In 2000, tungsten carbide rod total sale is 88.72 billion dollars and they accounted for 40% of it. 


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Tungsten Carbide Round Rod

Tungsten carbide round rod is a shape for round rod, and the main material for tungsten carbide round rod is tungsten carbide. Tungsten carbide, also known as cemented carbide, is an extremely hard alloy made from tungsten and carbon that offers high wear resistance as well as good corrosion resistance. These tungsten carbide round rods are used for the manufacture of cutting tools for the metal, wood, plastic and other industries where hardness and wear corrosion resistance is required. Tungsten carbide round rods are available in standard lengths of 310 and 330 mm.

Tungsten carbide round rod has been ground to achieve the precise shape and size, and has a precision tolerance. The tungsten carbide round rod provides high wear resistance, and good corrosion and heat resistance. Tungsten carbide round rod is mainly applied in making drills, end mills and reamers. And it is also used for cutting, punching and measuring tools.


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Tungsten Carbide Rod Corrosion Resistance in PH Value

Although tungsten carbide rod with cobalt binder has fairly good resistance to attack by acetone, ethanol, gasoline and other organic solvents as well as by ammonia, weak acids, and tap water. Exposure to formic, hydrochloric, hydrofluoric, nitric, phosphoric, sulfuric, and other strong acids, however, can result in a relatively rapid deterioration of the binder phase. Corrosion rates are affected also by temperature, the concentration and electrical conductivity of the corrosive agent, and by other environmental factors.

The following chart is the corrosion resistant details of tungsten carbide rod cobalt binder& tungsten carbide rod nickel binder in PH value. 

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International solid carbide cutting tools industry status is mainly reflected in the following two aspects:

First, international solid carbide cutting tools industry status is reflected in that the output value of international solid carbide cutting tools the international is about $ 1.3 billion, of which PCB drill and micro-milling of 600 million (about 20% of micro cutter), the average unit price of 1 USD / support, about $ 600 million; metalworking of solid carbide cutting tools around 25 million (60 million or more cutters), the average price is about $ 30, with a total of about $ 700 million.

Secondly, international solid carbide cutting tools industry status is reflected in that the forefront of the solid carbide cutting tools is Germany, accounting for 60% market share. Asia, China, Japan, South Korea accounted for about 25%, North America 15%.
 

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Tungsten carbide rod bending and deformation affecting factors includes carbon gradient, cobalt gradient, temperature gradient and density gradient.

1.Carbon gradient. During the dewaxing and sintering process the carbon gradient would change continuously. Due to the different parts of the tungsten carbide rod has different decarburization and carbon pick-up capability, carbon gradient then comes into being. Setting time in different parts also changes which causes liquid phase moves to the setting section first and cause the bending and deformation of tungsten carbide rod.

2.Cobalt gradient. During the vacuum sintering process of tungsten carbide rod, the wettability of the cobalt for different parts causes the liquid cobalt moves ups and downs.

3.Temperature gradient. During sintering process, liquid cobalt often moves to the high temperature section. The higher the temperature, the higher the cobalt contents will be, thus the deformation of tungsten carbide rod will be more serious.

4.Density gradient. Due to the insufficient pressure and uneven surface of rolled material, density gradient becomes another important factor. Normally, tungsten carbide rod with low density will bend and deform more easily.


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China tungsten carbide cutting tools industry status mainly in the following two ways:

First, China tungsten carbide cutting tools industry status reflects in that even though several large companies in the country can produce high strength, high hardness ultrafine alloy, it is difficult to meet the automotive, aerospace large manufacturing of tungsten carbide cutting tools of high strength, high wear resistance, high stability requirements. Although domestic tungsten carbide cutting tools in the price of imports relative to the tool by the advantages, however, the stability is at a disadvantage.

Secondly, China tungsten carbide cutting tools industry status reflects in that the researches on tungsten carbide cutting tool are relatively backward. Domestic researches on cemented carbide tool data has not been a big investment, the study on tungsten carbide cutting tools process is little, tungsten carbide cutting tools design also stays in the mapping, generic, low-level substitute imported products.

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Inserts welded of tungsten carbide cutting tools is a very important process. Due to chemical composition and mechanical properties of carbide and steel is completely different, often in the welding prone to cracking and welding which makes tungsten carbide cutting tools scrapped.

Tungsten carbide cutting tools welding crack caused by excessive stress. After sufficient heating, tungsten carbide cutting tools cooling starts, weld solidification. Since the thermal expansion coefficient of steel is 2-3 times larger than the carbide to produce different shrinkage in steel and cemented carbide, after reaching room temperature, the contraction of steel when carbide twice. The result is a gradual contraction tensile stresses in the tungsten carbide cutting tools which results in tungsten carbide cutting tools welding crack. Further, in the cemented carbide 950 ° C-1100 ° C will produce vigorous oxidation, the oxide film formed brittle carbide leaving many voids, thereby reducing the mechanical properties of tungsten carbide cutting tools. Thus, during welding, it is necessary to avoid oxidation of the welding area.

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As lather boring is a cutting process to generate conical or cylindrical surfaces on a pre-existing hole in a workpiece, the tungsten carbide cutting tools applied on are usually single-point cutting tools or boring head.



Lathe boring usually requires that the workpiece be held in the chuck and rotated. As the workpiece is rotated, a boring bar with an carbide insert attached to the tip of the bar is fed into an existing hole. When the tungsten carbide cutting tool engages the workpiece, a chip is formed. For non-tapered holes, the cutting tool moves parallel to the axis of rotation. For tapered holes, the cutting tool moves at an angle to the axis of rotation.

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It is known that boring is a process meant to increase a pre-existing hole in the machining. Usually ,tungsten carbide boring cutter is a single point cutting tool , made from carbide. The adjustable dimensions between the pieces and the tool bits enable the vertical cutting and horizontal cutting into internal surface.



The design concepts of boring cutter related to lower the product tolerances on holes that already have been drilled are need to be addressed. First, large length-to-bore-diameters are not preferred due to cutting tool deflection. Next, through holes are preferred over blind holes (holes that do not traverse the thickness of the work piece). Interrupted internal working surfaces, where the cutting tool and surface have discontinuous contact are preferably avoided. The boring bar is the protruding arm of the machine that holds cutting tools, which should be very rigid.


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