Gradient Cemented Carbide Mining Insert for Wear and Toughness
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cemented carbide mining inserts do not optimally balance toughness and wear resistance across different parts of the product, necessitating improved properties for enhanced durability and performance.
Innovation Solution
A method involving the addition of chromium (Cr) to the cemented carbide powder blend with a controlled mass ratio of Cr to binder, combined with a grain refiner compound and carbon-based grain growth promoter, to create a chemical and hardness gradient in the insert, enhancing wear resistance and toughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a higher binder content is used to increase toughness, then the toughness is improved, but the hardness and wear resistance decrease
Solution Approach 1:
The patent applies local quality by creating a gradient in binder content and grain size across different regions of the cemented carbide body. The interior region has higher binder content for toughness, while the exterior region has lower binder content for hardness and wear resistance, allowing both contradictory requirements to be satisfied in different locations.
Solution Approach 2:
The patent segments the cemented carbide body into distinct zones with different material properties. By dividing the homogeneous structure into gradient zones (interior with higher binder content versus exterior with lower binder content), the patent resolves the contradiction between toughness and wear resistance by assigning different functional characteristics to different segments.
2Reliability
If a finer hard phase grain size is used to increase hardness, then the wear resistance is improved, but the impact resistance decreases
Solution Approach 1:
The patent implements local quality by creating a gradient in hard phase grain size across the cemented carbide body. The exterior region has finer grain size for enhanced wear resistance, while the interior region has coarser grain size for improved impact resistance, allowing both requirements to be met simultaneously in different locations.
Solution Approach 2:
The patent segments the grain structure into zones with different grain sizes. By dividing the uniform grain structure into gradient zones (finer grains at the exterior versus coarser grains at the interior), the patent resolves the contradiction between wear resistance and impact resistance by assigning different grain size characteristics to different segments.
3Ease of manufacture
If a homogeneous material structure is used, then the manufacturing process is simple, but the operative performance is limited
Solution Approach 1:
The patent applies parameter changes by systematically varying the binder content and grain size parameters across the cemented carbide body. By creating controlled gradients in these parameters from the interior to the exterior, the patent achieves superior operative performance while maintaining manufacturing feasibility through established gradient formation techniques.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces cemented carbide mining inserts with improved wear properties and extended lifespan by introducing a chemical and hardness gradient, resulting in increased compressive stress and corrosion resistance.
Implementation Method 1
applying a second powder comprising a grain refiner compound and/or a carbon based grain growth promoter to at least one portion of the surface of the green mining insert compact
Implementation Method 2
sintering the green mining insert compact to produce a cemented carbide mining insert
Implementation Method 3
said the first powder additionally comprises Cr, in an amount such that the mass ratio of Cr/binder is of 0.01-0.3
Data Source
AI summary
The present disclosure relates to a method of making a cemented carbide mining insert, a cemented carbide mining insert with having a chemical and hardness gradient and to the use thereof. The method includes the steps of providing a green mining insert compact formed from a first powder including a WC-based hard phase, optionally one or more further hard-phase components and a binder, applying a second powder including a grain refiner compound and/or a carbon based grain growth promoter to at least one portion of a surface of the green mining insert compac, and sintering the green mining insert compact to produce a cemented carbide mining insert, wherein the first powder additionally includes Cr, in an amount such that the mass ratio of Cr/binder is of 0.01-0.3.