Optimisation of the WC-Co Composite Manufacturing Process Using Spark Plasma Sintering Technology with the DOE...

Area of Science:

• Materials Science and Engineering
• Powder Metallurgy
• Mechanical Engineering

Background:

• Tungsten carbide-cobalt (WC-6Co) composites are critical in wear-resistant applications.
• Optimizing the spark plasma sintering (SPS) process is essential for achieving desired material properties.
• Cost-effective process planning requires efficient experimental strategies.

Purpose of the Study:

• To optimize the spark plasma sintering (SPS) process for WC-6Co composite consolidation.
• To determine the key process parameters influencing the densification and properties of WC-6Co.
• To apply the Design of Experiments (DOE) methodology for efficient process optimization.

Main Methods:

• Utilized the Design of Experiments (DOE) methodology with an L9 orthogonal array.
• Investigated four key sintering factors: temperature (1300-1400 °C), heating rate (100-300 °C/min), time (150-600 s), and pressure (40-50 MPa).
• Performed validation experiments based on the statistical model predictions.

Main Results:

• Sintering temperature and heating rate were identified as the most influential factors on apparent density.
• Optimized SPS conditions yielded a WC-6Co composite with 97.42% theoretical density (14.85 g/cm³).
• Achieved high hardness (1809 HV30) and low total porosity (2.583%).

Conclusions:

• The Design of Experiments (DOE) methodology effectively optimized the spark plasma sintering of WC-6Co.
• The developed statistical model accurately predicted the consolidation behavior.
• The optimized process resulted in a high-performance WC-6Co composite suitable for demanding applications.