Gradient Cemented Carbide Mining Insert for Toughness and Wear
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cemented carbide mining inserts do not fully optimize the combination of toughness and wear resistance, leading to suboptimal performance and longevity in mining applications.
Innovation Solution
A method of producing cemented carbide mining inserts with a chemical and hardness gradient by using a first powder comprising WC-based hard phase, binder, and Cr, and applying a second powder with a grain refiner compound and/or carbon-based grain growth promoter, followed by sintering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a higher binder content is used, then the toughness of the cemented carbide is improved, but the hardness and wear resistance deteriorate
Solution Approach 1:
The patent applies different binder contents to different regions of the cemented carbide insert. The bulk region contains a higher binder content (10-15 wt%) to provide toughness and prevent catastrophic failure, while the surface region contains a lower binder content (5-10 wt%) to provide hardness and wear resistance. This spatial variation in composition resolves the contradiction between toughness and wear resistance.
Solution Approach 2:
The insert is divided into distinct regions (bulk and surface) with different material properties. The surface layer is separated from the bulk material through a selective process where the surface region experiences different sintering conditions or material composition, creating a functionally graded structure that simultaneously achieves toughness in the bulk and wear resistance at the surface.
2Reliability
If a finer hard phase grain size is used, then the hardness and wear resistance are improved, but the impact resistance deteriorates
Solution Approach 1:
The patent implements different grain sizes in different regions of the insert. The surface region contains finer hard phase grains (0.5-2 μm) to maximize hardness and wear resistance, while the bulk region contains coarser grains (2-5 μm) to provide impact resistance and toughness. This local differentiation resolves the contradiction between wear resistance and impact resistance.
3Ease of manufacture
If a uniform composition is used throughout the insert, then the manufacturing process is simplified, but the operative performance and longevity are suboptimal
Solution Approach 1:
The patent varies the composition parameters (binder content, hard phase grain size) as a function of position within the insert. By changing these parameters from the bulk to the surface region, the patent creates a functionally graded material that optimizes performance for both toughness and wear resistance, thereby extending service life despite the increased manufacturing complexity.
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 resulting cemented carbide mining inserts exhibit improved wear resistance and extended lifespan, achieving a balanced combination of toughness and hardness through the optimized chemical and hardness gradient.
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 compact, 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.