What is carbide and what are its properties?

Carbide is a material specially developed for applications that require high levels of hardness and resistance. Its chemical resistance makes carbide resistant to corrosion and aggressive substances, enabling it to be used in demanding environments. Its high density also makes it heavier than many other metals, steels and alloys.

How is carbide produced and what processes are used for this?

Two components are required for the production of carbide: A hard material, usually tungsten carbide (WC), and a binder, usually cobalt (Co). These two metal powders are mixed using powder metallurgy, pressed into moulds under high pressure and then heated by sintering without melting. Sintering ensures that the particles are firmly bonded together and the material retains its characteristic hardness. Other processes such as grinding and polishing are often used for final machining to achieve the desired surface qualities and precision.

What are the applications for carbide and which industries use it?

Carbide is used in numerous industries and machining operations where high levels of hardness, wear resistance and precision are needed. In metalworking, carbide is used for dies and punches in presses and punching processes, as it can withstand high mechanical loads and offers a long tool life. Carbide is used in drill bits, milling tools for road construction and rock drills. Its high wear resistance means it can be used to machine rock, concrete and other hard materials and thus extends the tool life. Carbide is also used for products such as bearings, nozzles and valves that are subject to constant abrasion or chemical exposure. In medical technology, carbide is used for instruments such as scalpels, milling cutters and drills that require high precision and durability while still providing good cutting sharpness.

How does carbide differ from other metals and alloys?

Carbide differs from steel, ceramic and HSS (high-performance high-speed steel) in several regards: It combines the hardness of carbides with the toughness of a binder metal, increasing its performance and making it much more economical than other materials. Unlike conventional steel, carbide remains stable even at high temperatures and deforms less under pressure. Other materials such as high speed steel (HSS) are more flexible, but wear out more quickly and lose their sharpness under intense use.

How can we measure and improve the wear resistance of carbide?

The wear resistance of carbide is usually measured by special abrasion tests in which the material is subjected to stresses under controlled conditions in order to analyse the material loss. Test methods such as the three-disc wear test or the abrasive wear test are used to document abrasion and crack formation. To improve wear resistance, the composition of the carbide can be optimised, for example by adjusting the cobalt content or adding other carbides such as titanium carbide. In addition, fine-grained tungsten carbides contribute to higher hardness and thus better wear resistance. Coatings provide additional protection against wear.

Which cutting tools can be manufactured from carbide and what are their properties?

Drills and milling cutters for machining metal are often made of carbide to guarantee that they retain their sharp cutting edges and achieve a long tool life, even at high speeds.

How do coatings affect the properties of carbide tools?

The coating of carbide is a decisive factor in further improving the tools' already high performance and tool life. Coatings also help to reduce friction between the tool and workpiece, making the machining process more efficient and smoother. 

What role does carbide play in modern manufacturing and what developments can we expect to see in this field?

Carbide plays a central role in modern manufacturing. Due to its hardness and wear resistance, it helps to reduce machining times and increase the efficiency of manufacturing processes. Future developments will focus on improving carbide compositions and integrating new coatings to further increase performance and tool life. Sustainability is also playing an increasingly greater role, with the focus on recycled carbide materials and resource-saving manufacturing processes. In addition, we expect to see carbide being combined with digital production technologies, such as additive manufacturing, which will enable even more precise and unique tools to be built.