A promising substitute for tungsten carbide in cutting tools is a tool coated with a solid layer of diamond obtained by diamond powder sintering. This substitute is particularly effective due to the superior hardness of diamond, which is necessary for tasks that require the machining of materials as hard as tungsten carbide.
Explanation of Substitute: The substitute for tungsten carbide, particularly in cutting tools, is a tool coated with polycrystals of diamond (PCD). This coating is achieved through a process of diamond powder sintering, which involves the consolidation of diamond particles under high pressure and temperature to form a solid, wear-resistant layer. The use of diamond as a coating material is strategic because diamond is the hardest known natural material, making it ideal for cutting and grinding applications that require high precision and durability.
Comparison with Tungsten Carbide: Tungsten carbide itself is a very hard material, comparable in hardness to corundum, and is typically used in applications where high wear resistance and hardness are required. However, the challenge with tungsten carbide, especially when dealing with pure tungsten, is its difficulty in machining due to its high ductile-to-brittle transition temperature. This makes it challenging to work with using conventional diamond tools, as the tungsten can become compacted between the diamonds, a phenomenon known as loading, which renders the cutting tool ineffective.
In contrast, tools coated with PCD are not only capable of machining tungsten carbide but also offer superior performance in terms of wear resistance and cutting efficiency. The diamond coating prevents the issue of loading and provides a sharper, more durable cutting edge.
Conclusion: The use of diamond-coated tools as a substitute for tungsten carbide in cutting applications is a significant advancement in materials technology. This substitution not only addresses the challenges associated with machining tungsten carbide but also enhances the overall efficiency and longevity of cutting tools. The application of PCD coatings is particularly beneficial in industries where precision and durability are paramount, such as in the manufacturing of industrial machinery and high-precision instruments.
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