WC Precious Metal Composites via FAST Sintering

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Solution Overview

Problem

Tungsten carbide-based materials face limitations due to their susceptibility to decomposition when melted, embrittlement in acidic environments, and cytotoxicity from nickel and cobalt, restricting their use in medical, pharmaceutical, and food-related applications, and requiring alternative binder phases for enhanced biocompatibility and corrosion resistance.

Innovation Solution

A method using field-assisted sintering (FAST) to produce tungsten carbide composite materials with gold, palladium, or platinum as binder phases, resulting in materials that are resistant to acidic environments and complexing agents, reducing cytotoxicity, and maintaining high hardness and biocompatibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If cobalt or nickel is used as binder phase in tungsten carbide cemented metals, then good wettability and binding strength are achieved, but cytotoxicity and delamination in acidic environments occur

Engineering Contradiction:

Improvebinding strengthVSAvoidcytotoxicity

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The invention changes the chemical composition parameter of the binder phase by replacing toxic cobalt and nickel with non-toxic precious metals (gold, palladium, platinum), thereby eliminating cytotoxicity while maintaining binding functionality through the sintering process

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite material system combining tungsten carbide with precious metal binders, where the precious metals provide both the binding function and biocompatibility, resolving the contradiction between strength and cytotoxicity

Inventive Principle:

Principle #40Composite materials

2Strength

If cobalt or nickel is used as binder phase, then binding strength is achieved, but delamination and embrittlement occur in acidic environments

Engineering Contradiction:

Improvebinding strengthVSAvoidcorrosion resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The invention changes the chemical composition of the binder phase to precious metals that are resistant to acid corrosion, eliminating delamination and embrittlement issues while maintaining binding strength through the sintering process

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses precious metals which, although expensive, provide long-term durability and corrosion resistance, preventing premature failure from delamination in acidic environments

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of manufacture

If conventional sintering processes are used to produce tungsten carbide materials, then manufacturing simplicity is maintained, but W2C impurity formation occurs

Engineering Contradiction:

Improveprocess simplicityVSAvoidpurity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The invention changes the sintering parameters by applying pulsed direct current during the sintering process, which enables precise control of the sintering conditions to prevent W2C impurity formation while maintaining process feasibility

Inventive Principle:

Principle #35Parameter changes

4Manufacturing precision

If field-assisted sintering with pulsed direct current is used, then manufacturing precision and purity are improved, but process complexity increases

Engineering Contradiction:

ImprovepurityVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention replaces conventional thermal sintering with field-assisted sintering using pulsed direct current, where electrical energy substitution for thermal energy enables precise control and high purity while maintaining reasonable process complexity through established FAST technology

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 FAST process enables the production of tungsten carbide composite materials with improved biocompatibility, corrosion resistance, and mechanical properties, expanding their application in medical, pharmaceutical, and food technology, while minimizing contamination and embrittlement issues.

Implementation Method 1

heating the powder mixture to a sintering temperature by means of a pulsed direct current

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

applying a pressure to the powder mixture

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 3

sintering the powder mixture

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentEP3762165B1Process for production of composite materials based on tungsten carbide with precious metal binders

Publication Date: 2023.07.12 HNP MIKROSYST

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AI summary

The invention relates to composite materials based on tungsten carbide and comprising gold, palladium and/or platinum and to a method for producing said composite materials by sintering. By means of the FAST method, hard and biocompatible WC/(Au, Pd, Pt) composite materials can be produced, inter alia for use as coatings on tools and prostheses and as solid bodies in, for example, blood pumps.