Much of the equipment used in the Oil & Gas industry is subject to an aggressive environment that must not only resist erosion from high velocity fluids containing sand particles and other abrasive media, but it must also be resistant to corrosion damage. The combination of these two factors has caused this industry to migrate towards using more components that are made from Cemented Carbide. These components have natural properties that tend to resist such wear resistant mechanisms; however, Sandvik Hard Materials has dramatically improved the resistance to erosion and corrosion by focusing on the binder phase of grades used in this field. In order to improve the wear characteristics of the Cemented Carbide grades used specifically for choke valves in this industry, multi-binder (Ni, Cr, Mo, and Co) corrosion/erosion resistant materials were introduced.

Today, there are more than 100 choke control valves in service using these Cemented Carbide grades operating in subsea and other extreme environments. These materials have contributed to an improvement of up to 5 times service life when compared to conventional grades. Sandvik Hard Materials has now taken this performance increase to another level. Based on feedback gained from the field and the experiences of equipment design engineers working with these grades, Sandvik has carried out development work focused on improving material toughness and strength. Success has been achieved by carefully optimizing the relationship between wear (material hardness) and toughness for the multi-binder materials without any loss of resistance to corrosion or erosion.
 

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Extremely fine grain sizes for the smallest holes

The progressive miniaturization of printed circuit board design requires ever smaller cutting tools. In order to meet performance requirements in terms of wear resistance, rigidity and toughness.

Today the trend is miniaturization: digital cameras, laptops and mobile phones become smaller and should include more features. To be able to meet this demand the PCB manufacturers have to drill more and smaller holes (less than 0,1 mm) carbide components and carbide tools can develop spindles with increasing rpm, to facilitate the use of very small drills and to increase productivity.

The grades for the PCB drill blanks industry have been developed through an extensive research program which utilizes an entirely new patented Cemented Carbide processing technology. This new process ensures that the Tungsten Carbide (WC) grain size is maintained within narrow limits and that the Cobalt (Co) binder phase is distributed in such a way as to fully maximize strength and toughness at all hardness levels.

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Add value to your pumps and drilling devices and complete product range.

Wear resistance, toughness, corrosion resistance, and resistance to thermal shock are the key material properties required for long-lasting, all-perfect pump function.

The unique combination of all these material characteristics has made Cemented Carbide the most widely used material in carbide tools as pump seals and bearing in the sewage, mining and process sectors. Moreover, there is further potential to tailor Cemented Carbide for a vast range of environmental applications.

Sandvik grades offer a complete set of properties

■Excellent hardness / toughness compromise guarantees outstanding wear, erosion and shock resistance
■Robust surface
■Low friction coefficient and high mechanical strength
■High thermal conductivity and superior thermal resistance
■Resistant to handling and easy to assemble
■Support brazing, mechanical assembling, shrink fitting, press fitting and gluing

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Combine excellent pass form wear resistance with high strength and toughness in the roll body.

Carbide tools and carbide components optimizes the hot rolling mills. The cast-in-carbide (CIC) concept takes this material a step further, as demonstrated in hot rolling mills all over the world. The CIC technology offers new opportunities for rolling mill managers to improve product quality, reduce down-time and increase productivity. Cemented Carbide manufacture is a highly specialized area, involving many different metallurgical, chemical and mechanical processes. The main stages from powder to finished roll blank are pressing, shaping and sintering. A pressing capacity of up to 1,200 tons places our powder pressing facilities in a class of their own. In the direct sintering process, the shaped blanks are heat-treated to a well-defined temperature and time exposure, depending on the particular carbide grade.

Carbide rolls have reached their correct hardness after the sintering process is complete. This hardness makes the rolls very difficult to machine. Because of this difficulty, it is important that we engineer each product to be as close as possible to their final dimension during the manufacture of the blanks. Grinding is normally utilized for machining the final roll shape. Grades with 25 and 30% binder can also be machined by turning.

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Adapted grades offering to meet the performance and production techniques adopted by the customers

Metal Cutting
Cemented Carbide and Cermet grades provide the toolmaker with a productivity solution for different applications and cutting conditions, extending tool life and ease of tool fabrication.There are grades suitable for example for non-ferrous cutting applications, where the saw blade cuts through materials as UPVC and aluminum, as for interrupted cutting applications.

Wood Cutting
Cemented Carbide and Cermet grades provide the toolmaker with improved edge quality without reduction in brazing and grinding characteristics.

A grade offering for Wood Cutting has been developed by extensive research and development into the cutting characteristics needed for circular saws. Through the introduction of DC (anti- corrosive) and DH (next generation) grades we provide materials that give optimum performance for wood cutting tools.

In today's competitive Oil & Gas drilling environment, the pursuit of faster, economical and superior wells has conjured a host of technological advances.

However, in the end, it all comes down to the drilling bit. Cemented Carbide is an ideal material for drilling inserts and carbide drill bits due to its high hardness, compressive strength and thermal conductivity. Research and Development within Sandvik Hard Materials has taken these properties and used innovative techniques to improve the toughness and impact resistance, while reducing the risk of thermal effects of the carbide drill bits during drilling.

The variety of material that Sandvik can supply provides coverage for a variety of application needs. In soft rock/heat generation formations, engineers typically select grades that are extra coarse with high binder content. These characteristics result in high fracture toughness and prolonged carbide drill bit life. Medium coarse grades with low binder content are generally used in drilling hard formations. This results in high hardness (better abrasion resistance), but low fracture toughness, ultimately having a higher penetration rate but increased likelihood for fracture.

Sandvik manufactures a large variety of inserts and carbide drill bits used in rotary & percussion rockbits for Oil & Gas and mining industries. Extreme drilling conditions, whether rotary, percussion or downhole, require unique solutions. Sandvik has the technology to supply the customers with inserts and carbide drill bits that perform every time.

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Material selection, be it different steel and/or carbide grades, plays an important role on tool life. Choosing the correct tool materials for the application, you can optimize performance and life, thus lowering your tooling cost per can. When creating a tooling solution for 2 and 3 piece cans and aerosols, tooling specifications need to be clearly defined. Can manufacturing is a very sophisticated process, consisting of several different components that work together to keep the production line running.

The malfunction of even one of these components will result in the stoppage of production. The unique composition of Cemented Carbide provides stability and high productivity in production, DWI process, forming and stamping operations in the can manufacturing industry, which makes Cemented Carbide the ideal tool material.

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Cemented Carbide was not commonly perceived as an automotive material. In reality, Cemented Carbide and Cermets offer a wide range of properties making them very well suited for the new challenges of the automotive industry. Carbide components have been developing and supplying solutions for the automotive industry for decades. Cemented Carbide, related Cermets and carbide components provide the automotive industry tailored solutions from carbide tools to a wide variety of automotive applications.

Cemented Carbide is already successfully used in a variety of automotive applications such as fuel pumps, fuel injectors, compressors and valve trains. With pressures commonly reaching 1600 bars and planned to rise shortly to 2000 bars and higher, Cemented Carbide bring many valuable properties to these applications.
 

Cemented Carbide provides resistance to high temperatures, corrosive environments, high compressive stress, fatigue and many other harsh conditions.
 

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Carbide components are improving the productivity of applications in metal-cutting, mining, mineral and civil engineering, agriculture, food processing and textiles, just to name a few.

The Aerospace Industry above all other demands exceptional performance with the highest level of operational reliability. Cemented Carbide is chosen for such demanding applications as bearing parts for helicopters, fuel pumps and hydraulic components in jet engines. Cemented Carbide components are also chosen to resist the wear experienced in many aspects of food processing. Carbide nozzles and homogenizers are used in the dairy and beverage sectors, carbide crusher parts for cocoa production and cutting knives. Another example is recycling, transforming old scrap into secondary raw materials that can be fed back into the manufacturing process. Sandvik Hard Materials provides Cemented Carbide parts for recycling machines. This ensures a long life on components used to crush waste glass, wood, plastic, rubber, paper etc.
 

Although Wear Parts can be found in a very diverse range of industrial and domestic sectors, they all have one thing in common: the critical need for resistance to impact, corrosion and wear.

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This group of Cemented Carbides contains WC and Co only (i.e. two phases) and a few trace elements. These grades are classified according to their cobalt content and WC grain size.

The grades with binder content in the range 10-20% by weight and WC-grain sizes between 1 and 5 μm have high strength and toughness, combined with good wear resistance.
The grades with binder contents in the range 3-15% and grain sizes below 1 μm have high hardness and compressive strength, combined with exceptionally high wear resistance.

 
Microstructure of γ-phase grade

The Sandvik grade program also includes WC-Co grades which utilize a range of ultra-fine WC grain sizes (< 0.5 μm). With such fine, uniform grain sizes, a unique combination of hardness, wear resistance and toughness can be achieved.

The grades of Cemented Carbides in this group contain WC and Co as the main elements, although small additions or trace levels of other elements are often added to optimize properties. These grades are classified according to their Cobalt content and WC grain size and are often called the "straight grades". They have the widest range of strength and toughness of all the Cemented Carbide types and this is in combination with excellent wear resistance.

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