Where can Cemented Carbide be used?
Carbide components are improving the productivity of applications in metal-cutting, mining, mineral and civil engineering, agriculture, food processing and textiles, just to name a few.
The Aerospace Industry above all other demands exceptional performance with the highest level of operational reliability. Cemented Carbide is chosen for such demanding applications as bearing parts for helicopters, fuel pumps and hydraulic components in jet engines. Cemented Carbide components are also chosen to resist the wear experienced in many aspects of food processing. Carbide nozzles and homogenizers are used in the dairy and beverage sectors, carbide crusher parts for cocoa production and cutting knives. Another example is recycling, transforming old scrap into secondary raw materials that can be fed back into the manufacturing process. Sandvik Hard Materials provides Cemented Carbide parts for recycling machines. This ensures a long life on components used to crush waste glass, wood, plastic, rubber, paper etc.
Although Wear Parts can be found in a very diverse range of industrial and domestic sectors, they all have one thing in common: the critical need for resistance to impact, corrosion and wear.
Cemented Carbide was not commonly perceived as an automotive material. In reality, Cemented Carbide and Cermets offer a wide range of properties making them very well suited for the new challenges of the automotive industry. Carbide components have been developing and supplying solutions for the automotive industry for decades. Cemented Carbide, related Cermets and carbide components provide the automotive industry tailored solutions from carbide tools to a wide variety of automotive applications.
Cemented Carbide is already successfully used in a variety of automotive applications such as fuel pumps, fuel injectors, compressors and valve trains. With pressures commonly reaching 1600 bars and planned to rise shortly to 2000 bars and higher, Cemented Carbide bring many valuable properties to these applications.
Cemented Carbide provides resistance to high temperatures, corrosive environments, high compressive stress, fatigue and many other harsh conditions.
Material selection, be it different steel and/or carbide grades, plays an important role on tool life. Choosing the correct tool materials for the application, you can optimize performance and life, thus lowering your tooling cost per can. When creating a tooling solution for 2 and 3 piece cans and aerosols, tooling specifications need to be clearly defined. Can manufacturing is a very sophisticated process, consisting of several different components that work together to keep the production line running. The malfunction of even one of these components will result in the stoppage of production. The unique composition of Cemented Carbide provides stability and high productivity in production, DWI process, forming and stamping operations in the can manufacturing industry, which makes Cemented Carbide the ideal tool material.
Carbide Rotary Cutters
Using Carbide Rotary Cutters, your converting line will face no restrictions in the cutting function (up to 1800 pieces/min). Carbide tools made with carbide components are both harder and stiffer with superior thermal conductivity compared with steel, which makes Cemented Carbide ideal for Carbide Rotary Cutters. It is possible to resharpen the Carbide Rotary Cutters several times during their lifetime. Cemented Carbide properties make the Carbide Rotary Cutter surpass conventional cutter performance. There is no deformation of the cutting edge and there is an increased cutting load compared to steel. There are no speed limitations due to the strong performance of the cutting edge.
Metal Forming Tools
Back-relief angle and bearing geometry are the best key factors in achieving rapid die finishing and the best die performance. In particular for the smallest bores, drawing and exit cones must be perfectly co-axial in order to achieve an accurate final geometry. With Cemented Carbide, one can manufacture tools and drawing nibs for the full range of wire drawing applications as High-carbon wire, Steel cord for rubber reinforcement, Bead wire, Welding wire, Stainless steel wire, Spring wire, etc.
A long experience and commitment to research and development enables Sandvik to offer a range of carbide grades to meet the drawing requirements for all applications.
H3F contains 3% cobalt and has a true sub-micron WC grain size. It is the benchmark for leading edge wet drawing of tire cord wire. Sandvik continually develops new grades and materials in order to offer improved performance to the industry.
Oil & Gas Applications
Much of the equipment used in the Oil & Gas industry is subject to an aggressive environment that must not only resist erosion from high velocity fluids containing sand particles and other abrasive media, but it must also be resistant to corrosion damage. The combination of these two factors has caused this industry to migrate towards using more components that are made from Cemented Carbide. These components have natural properties that tend to resist such wear resistant mechanisms; however, Sandvik Hard Materials has dramatically improved the resistance to erosion and corrosion by focusing on the binder phase of grades used in this field. In order to improve the wear characteristics of the Cemented Carbide grades used specifically for choke valves in this industry, multi-binder (Ni, Cr, Mo, and Co) corrosion/erosion resistant materials were introduced. Today, there are more than 100 choke control valves in service using these Cemented Carbide grades operating in subsea and other extreme environments. These materials have contributed to an improvement of up to 5 times service life when compared to conventional grades. Sandvik Hard Materials has now taken this performance increase to another level. Based on feedback gained from the field and the experiences of equipment design engineers working with these grades, Sandvik has carried out development work focused on improving material toughness and strength. Success has been achieved by carefully optimizing the relationship between wear (material hardness) and toughness for the multi-binder materials without any loss of resistance to corrosion or erosion.
PCB drill blanks
The progressive miniaturization of printed circuit board design requires ever smaller cutting tools. In order to meet performance requirements in terms of wear resistance, rigidity and toughness.
Today the trend is miniaturization: digital cameras, laptops and mobile phones become smaller and should include more features. To be able to meet this demand the PCB manufacturers have to drill more and smaller holes (less than 0,1 mm) carbide components and carbide tools can develop spindles with increasing rpm, to facilitate the use of very small drills and to increase productivity.
The grades for the PCB drill blanks industry have been developed through an extensive research program which utilizes an entirely new patented Cemented Carbide processing technology. This new process ensures that the Tungsten Carbide (WC) grain size is maintained within narrow limits and that the Cobalt (Co) binder phase is distributed in such a way as to fully maximize strength and toughness at all hardness levels.
Rings and Bushing
Wear resistance, toughness, corrosion resistance, and resistance to thermal shock are the key material properties required for long-lasting, all-perfect pump function.
The unique combination of all these material characteristics has made Cemented Carbide the most widely used material in carbide tools as pump seals and bearing in the sewage, mining and process sectors. Moreover, there is further potential to tailor Cemented Carbide for a vast range of environmental applications.
Sandvik grades offer a complete set of properties
- Excellent hardness / toughness compromise guarantees outstanding wear, erosion and shock resistance
- Robust surface
- Low friction coefficient and high mechanical strength
- High thermal conductivity and superior thermal resistance
- Resistant to handling and easy to assemble
- Support brazing, mechanical assembling, shrink fitting, press fitting and gluing
Rolls for Hot Rolling
Carbide tools and carbide components optimizes the hot rolling mills. The cast-in-carbide (CIC) concept takes this material a step further, as demonstrated in hot rolling mills all over the world. The CIC technology offers new opportunities for rolling mill managers to improve product quality, reduce down-time and increase productivity. Cemented Carbide manufacture is a highly specialized area, involving many different metallurgical, chemical and mechanical processes. The main stages from powder to finished roll blank are pressing, shaping and sintering. A pressing capacity of up to 1,200 tons places our powder pressing facilities in a class of their own. In the direct sintering process, the shaped blanks are heat-treated to a well-defined temperature and time exposure, depending on the particular carbide grade.
Carbide rolls have reached their correct hardness after the sintering process is complete. This hardness makes the rolls very difficult to machine. Because of this difficulty, it is important that we engineer each product to be as close as possible to their final dimension during the manufacture of the blanks. Grinding is normally utilized for machining the final roll shape. Grades with 25 and 30% binder can also be machined by turning.
Cemented Carbide and Cermet grades provide the toolmaker with a productivity solution for different applications and cutting conditions, extending tool life and ease of tool fabrication.There are grades suitable for example for non-ferrous cutting applications, where the saw blade cuts through materials as UPVC and aluminum, as for interrupted cutting applications.
Cemented Carbide and Cermet grades provide the toolmaker with improved edge quality without reduction in brazing and grinding characteristics.
A grade offering for Wood Cutting has been developed by extensive research and development into the cutting characteristics needed for circular saws. Through the introduction of DC (anti- corrosive) and DH (next generation) grades we provide materials that give optimum performance for wood cutting tools.