FAQ
Frequently asked questions
The contents of past inquiries from customers are posted on this site. Please take a look.
Characteristics of cemented carbide
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What is the difference between cemented carbide and ceramics?
The hardness of ceramics approaches that of diamond, the hardest mineral on earth. If the hardness of diamond is 10, ceramics exhibit a hardness of 9 or higher, which is harder than tungsten and other hard metals. The difference in composition also results in a heavier weight in the case of cemented carbides. However, cemented carbides can be made with various characteristics depending on tungsten carbide (WC) particle size, the amount of bonding material, and additives, so it is possible to select the most suitable grade for the application from a wide range of available grades.
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What is the difference between cemented carbide and cermet?
Both cemented carbide and cermet are composite materials made by mixing and sintering carbide or nitride powders with a metallic binder.
However, whereas cemented carbides are made of tungsten carbide (WC), the main component, bonded mainly with cobalt (Co) and nickel (Ni),
Cermet is made by bonding titanium compounds such as titanium carbide (TiC) and titanium carbide nitride (TiCN) with nickel (Ni) and cobalt (Co).
In other words, the difference between cemented carbide and cermet is the main component. -
What is the difference between cemented carbide and HSS?
Cemented carbide is an alloy with high hardness, heat resistance and strength. HSS, on the other hand, generally has relatively lower strength and heat resistance, but has higher impact resistance.
As their raw materials and manufacturing methods differ, there is a significant difference in costs between the two materials.
Selecting the suitable material is recommended though considering the application and the timing of replacement after installation.
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What are the weaknesses of cemented carbides?
Compared to general iron alloys, cemented carbide has lower toughness, which may cause chipping or peeling of the cutting edge.
In addition, as the relative density is about twice that of iron, the heavier weight of cemented carbide may be a disadvantage. -
What causes cemented carbide to crack?
Compared to metal materials, cemented carbide materials have a different thermal expansion coefficient. For this reason, cracks may occur in shrink/cooling-fitted products when the operating temperature is significantly higher (lower) than the designed value. When using cemented carbides with high hardness, problems such as cracking may occur by high impact, so the required fracture toughness value should also be carefully considered.
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What kind of cemented carbide is used as cutting tools?
The material of cemented carbide to be selected depends on the workpiece and its thickness, etc. In general, for use as a cutting tool, ultrafine grain cemented carbide, which consists of ultrafine tungsten carbide (WC) particles, is often selected to increase cutting ability and to prevent chipping.
Carbide material selection
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Can A10W be considered for use in electrical machining?
We believe A10W can be used safely even in electrical machining.
Fine particle grain cemented carbide inhibit crack propagation through mixing coarse-sized grain, and the heat affected layer's thickness is reduced through lowering the amount of Co. This is why we recommend A10W for wire EDM. -
Which carbide material is the most resistant to abrasion?
The SS Grade carbide, made for abrasion resistance.
SS13 and SS15 have the hardness of HV2450 and HV2100, respectively.
These materials are not very tough, so it is recommended that you use them under a low load. -
We are using carbide for press processing of stainless materials, but compared to SPCC, abrasion occurs quickly and parts must be replaced.
Stainless materials are hard and tough, which leads to greater abrasion and chipping of the tool.
We recommend using KX01, as it has superior toughness and resistance to heat, and is extremely hard. -
We are using fine grain and ultra fine grain carbide parts with wire cutting and EDM machines, but chipping occurs often during use.
Try our A10W.
This material maintains the transverse rupture strength of KD20, while having resistance to thermal cracking during EDM/WEDM improved. -
What about working with pure iron, pure copper, and nickel?
The reason for a shorter lifespan is due to their affinity with cobalt contained in carbide.
We have received great praise for our MC20 that controls this adhesion with lowered affinity to these materials. -
What carbides have excellent chipping and abrasions resistance for cutting and bending materials of C5191, C5210 (phosphor bronze), and C1020 (pure copper)?
Results 1: C5191, C5210 (phosphor bronze): KD20
Results 2: C5210 stamping connector, die: KD40 punch:KD20 stripper:G4
Results 3: C5210 stamping/bending connector EF01
Results 4: C1020 (pure copper) MC20
Manufacturing Process
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About galling (seizure) of soft metal
By using metal mold with metal adhered to it, part of the metal will melts due to frictional heat and thus galling will occur.
Soft metals are more likely to adhere and cause galling.
Adhering: the bonding that occurs when 2 types of metals approach one another at an atomic level
Galling: the state when the friction factor increases suddenly from adhering or welding
Affinity mechanism: 1) Adhering > Galling > Affinity 2) Galling > Affinity -
What’s the difference between EDM cracks and heat affected layers?
Both occur from thermal energy during EDM. An heat affected layer is made of melted and solidified Co and WC particles, and a crack occurs from EDM impact or the stress of shrinkage from melting and solidifying.
An altered layer occurs only on part of the processed layer, but a crack may occur through the original material, as well. -
Can a carbide be fixed into position via magnetic fixture during processing?
While carbide is magnetic it is weak, making use of magnetic chucks dangerous.
We recommend using a vice, reinforcing plate, or bonding adhesive. -
I would like to have tapping applied to the carbide parts.
We recommend direct tapping. Tapping is done after taking into account the amount of shrinking that will occur during sintering.
It is tougher than electrical tapping or bush brazing.
If any pitch accuracy is required, we recommend electrical tapping or brazing.
Other Questions
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Is micro-grain cemented carbide lead time long?
No.
Because of our Micro-grain cemented carbide EF grade assembly line, we are able to deliver in the same time as other materials. -
I would like a short delivery time.
For cemented carbide materials, we stock blocks of each grade, and some are polished on two sides so that they can be used immediately by cutting.
We are establishing a system to enable sintering of molded materials at the current day, so please feel free to contact us.
we shorten the delivery for finished parts, jigs and tools by cutting them out from stocked blocks. -
How is lot management carried out? How frequent are checks on carbide grain structure made?
We check the structure and hardness of a test piece in a sintering furnace.
We check every single lot of powder when it is completed.
We check the external appearance of all products when sintered, and inspect the structure based on sampling method.
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