Content Menu
● What Is Cemented Carbide?
>> Key Properties of Cemented Carbide
● Why Cemented Carbide Is Ideal for Mining Tools
● Applications of Cemented Carbide in Mining Tools
>> 1. Drill Bits and Button Bits
>> 2. Cutting Picks and Shearer Picks
>> 3. Roller-Cutters and Reamers
>> 4. Crusher and Milling Components
>> 5. Conveyor Belt Scrapers
● Manufacturing Process of Cemented Carbide Mining Tools
>> 1. Powder Preparation
>> 2. Mixing and Spray Drying
>> 3. Pressing and Shaping
>> 4. Pre-Sintering and Sintering
>> 5. Grinding and Finishing
● Advantages of Using Cemented Carbide in Mining Tools
● Innovations and Future Trends in Cemented Carbide Mining Tools
>> Nano-Structured Cemented Carbide
>> Coating Technologies
>> Additive Manufacturing
>> Environmental and Economic Benefits
● Case Studies: Cemented Carbide in Action
>> Case Study 1: Coal Mining Efficiency Improvement
>> Case Study 2: Hard Rock Drilling
● Maintenance and Handling of Cemented Carbide Tools
● Conclusion
● Frequently Asked Questions (FAQ)
>> 1. What makes cemented carbide superior to steel in mining tools?
>> 2. How does the cobalt binder influence cemented carbide properties?
>> 3. Can cemented carbide tools be repaired or sharpened?
>> 4. What types of mining tools commonly use cemented carbide?
>> 5. How does cemented carbide improve mining operational efficiency?
● Citations:
Cemented carbide, also known as tungsten carbide, is a revolutionary material that has transformed the mining industry by significantly enhancing the efficiency, durability, and performance of mining tools. As a high-tech enterprise engaged in the research, production, and sales of cemented carbide products, we understand the critical role this material plays in demanding mining environments. This article explores how cemented carbide is used in mining tools to achieve better efficiency, detailing its properties, applications, manufacturing process, and benefits.
What Is Cemented Carbide?
Cemented carbide is a composite material made by embedding fine carbide particles, primarily tungsten carbide (WC), into a metallic binder, usually cobalt (Co). This combination results in a material with hardness second only to diamond, exceptional wear resistance, and remarkable toughness.
Key Properties of Cemented Carbide
- High Hardness and Wear Resistance: Cemented carbide exhibits a hardness of 86–93 HRA (equivalent to 69–81 HRC), maintaining this hardness even at elevated temperatures up to 900–1000°C. This property enables tools to cut through extremely hard materials.
- High Strength and Elastic Modulus: With compressive strength reaching 6000 MPa and a high modulus of elasticity, cemented carbide withstands heavy loads without deformation.
- Corrosion and Oxidation Resistance: It resists corrosion from acids, alkalis, and atmospheric exposure, making it durable in harsh mining conditions.
- Thermal Stability: Its high thermal conductivity allows efficient heat dissipation during high-speed cutting, preventing tool overheating.
- Dimensional Stability: A low coefficient of thermal expansion ensures that tools maintain precise dimensions during operation.
Why Cemented Carbide Is Ideal for Mining Tools
Mining operations subject tools to extreme wear, impact, and thermal stresses as they drill, cut, and crush rock and mineral formations. Cemented carbide's unique combination of hardness, toughness, and thermal stability makes it ideal for these applications, offering:
- Extended Tool Life: Cemented carbide tools last 5 to 80 times longer than high-speed steel tools, reducing downtime and replacement costs.
- Improved Cutting Efficiency: The ability to maintain sharp cutting edges at high temperatures allows faster cutting speeds and higher productivity.
- Resistance to Breakage: Despite being brittle compared to steel, the toughness imparted by the cobalt binder helps absorb impacts and reduce chipping.
- Versatility: Cemented carbide tools can be used across various mining applications, including drilling, cutting, tunneling, and crushing.
Applications of Cemented Carbide in Mining Tools
1. Drill Bits and Button Bits
- Tungsten carbide button bits are widely used in rock drilling for mining, tunneling, and civil engineering. These bits have cemented carbide inserts that provide high penetration rates, wear resistance, and durability.
- Different button shapes such as semi-ballistic, ballistic, chisel, double dome, and flat buttons are designed for specific rock hardness and drilling conditions, optimizing performance and tool life.
2. Cutting Picks and Shearer Picks
- Cemented carbide-tipped picks are used in longwall mining machines to cut coal seams efficiently. These picks provide up to 600% longer life and up to 30-40% increased cutting output compared to steel picks.
3. Roller-Cutters and Reamers
- Used in tunnel boring machines and raiseboring, cemented carbide roller cutters and reamers offer high cutting performance and wear resistance, enabling continuous mining operations with minimal tool changes.
4. Crusher and Milling Components
- Cemented carbide parts are employed in crushers and mills to reduce wear and extend service life, improving the efficiency of mineral processing.
5. Conveyor Belt Scrapers
- Tungsten carbide blades maintain conveyor belt cleanliness, reducing downtime and increasing productivity in mining operations.
Manufacturing Process of Cemented Carbide Mining Tools
The production of cemented carbide mining tools involves several precise steps to ensure optimal performance:
1. Powder Preparation
Tungsten oxide is mixed with carbon and processed into tungsten carbide powder. This powder is then blended with cobalt powder and other additives to achieve the desired hardness and toughness balance.
2. Mixing and Spray Drying
The powders are mixed uniformly in ball mills and spray-dried to obtain a powder with good flowability for pressing.
3. Pressing and Shaping
The powder mixture is pressed into the desired shape using CNC-controlled presses. This step forms the green body of the tool.
4. Pre-Sintering and Sintering
The pressed parts undergo pre-sintering at 600–1000°C to harden them enough for handling, followed by sintering at 1300–1500°C. During sintering, cobalt melts and bonds the tungsten carbide particles into a dense, hard composite.
5. Grinding and Finishing
Diamond grinding wheels shape the tools to precise dimensions. The cutting edges are carefully treated and often coated with wear-resistant layers such as titanium nitride (TiN) to further enhance tool life.
Advantages of Using Cemented Carbide in Mining Tools
| Advantage | Explanation |
| Longer Tool Life | Resists wear and breakage, reducing replacement frequency and maintenance costs. |
| Higher Productivity | Enables faster cutting speeds and drilling rates, improving overall mining efficiency. |
| Improved Precision | Maintains sharp edges and dimensional stability for accurate cutting and drilling. |
| Corrosion Resistance | Performs reliably in harsh chemical and environmental conditions. |
| Versatility | Suitable for a wide range of mining tools and rock types. |
| Cost Efficiency | Despite higher initial cost, longer lifespan and reduced downtime lead to better ROI. |
Innovations and Future Trends in Cemented Carbide Mining Tools
The mining industry continues to evolve, and so do the materials and technologies used in mining tools. Innovations in cemented carbide production and tool design are driving further improvements in efficiency and sustainability.
Nano-Structured Cemented Carbide
Recent advancements have led to the development of nano-structured cemented carbide, where the grain size of tungsten carbide is reduced to the nanometer scale. This refinement enhances hardness and toughness simultaneously, resulting in tools that can withstand even more extreme conditions and last longer.
Coating Technologies
Advanced coating technologies such as chemical vapor deposition (CVD) and physical vapor deposition (PVD) are being applied to cemented carbide tools to improve wear resistance and reduce friction. Coatings like titanium aluminum nitride (TiAlN) and diamond-like carbon (DLC) extend tool life and enable higher cutting speeds.
Additive Manufacturing
Additive manufacturing (3D printing) is beginning to be explored for producing complex cemented carbide components with optimized geometries that were previously impossible to manufacture. This technology promises to reduce material waste and production time.
Environmental and Economic Benefits
Using longer-lasting cemented carbide tools reduces the frequency of tool replacements, which lowers material consumption and waste generation. This contributes to more sustainable mining practices and reduces operational costs.
Case Studies: Cemented Carbide in Action
Case Study 1: Coal Mining Efficiency Improvement
A major coal mining company reported a 35% increase in cutting efficiency and a 50% reduction in tool replacement frequency after switching to cemented carbide-tipped shearer picks. This improvement led to significant cost savings and less downtime.
Case Study 2: Hard Rock Drilling
In hard rock mining, the use of tungsten carbide button bits with optimized button shapes increased penetration rates by 20%, allowing faster tunnel boring and reduced project timelines.
Maintenance and Handling of Cemented Carbide Tools
Proper maintenance and handling are crucial to maximize the lifespan of cemented carbide tools. Operators should avoid dropping or striking tools against hard surfaces to prevent chipping. Regular inspection and timely sharpening using diamond grinding wheels help maintain cutting performance.
Conclusion
Cemented carbide has become indispensable in the mining industry due to its exceptional hardness, toughness, and thermal stability. Its use in mining tools such as drill bits, cutting picks, reamers, and crusher components has led to significant improvements in tool life, operational efficiency, and cost savings. The advanced production processes ensure that each tool meets the rigorous demands of mining environments, delivering superior performance and reliability. Investing in cemented carbide mining tools is a strategic choice for mining operations aiming to maximize productivity and minimize downtime.
As a leading manufacturer specializing in the production of cemented carbide products, we are committed to providing high-quality, customized solutions that meet the specific needs of industrial, military, metallurgical, petroleum drilling, mining, and construction applications.
Frequently Asked Questions (FAQ)
1. What makes cemented carbide superior to steel in mining tools?
Cemented carbide offers much higher hardness and wear resistance than steel, allowing tools to cut harder materials faster and last significantly longer under harsh mining conditions.
2. How does the cobalt binder influence cemented carbide properties?
Cobalt acts as a metallic binder that provides toughness and impact resistance. Increasing cobalt content improves toughness but reduces hardness and wear resistance, so the ratio is optimized based on application requirements.
3. Can cemented carbide tools be repaired or sharpened?
Yes, cemented carbide tools can be sharpened using specialized diamond grinding equipment. However, due to their hardness, sharpening requires precision and care to avoid damage.
4. What types of mining tools commonly use cemented carbide?
Common tools include drill bits (button bits), cutting picks, shearer picks, roller cutters, reamers, crusher liners, and conveyor belt scrapers.
5. How does cemented carbide improve mining operational efficiency?
By extending tool life, enabling higher cutting speeds, reducing downtime for tool changes, and providing consistent cutting performance, cemented carbide tools significantly boost mining productivity and cost-effectiveness.
Citations:
[1] https://www.yatechmaterials.com/en/news/cemented-carbide-in-oil-and-gas-industry/
[2] https://www.carbide-part.com/blog/cemented-carbide-properties-advantages-and-areas-of-application/
[3] https://www.azom.com/article.aspx?ArticleID=18084
[4] https://www.basiccarbide.com/mining-industry-carbide/
[5] https://www.istockphoto.com/photos/tungsten-carbide
[6] https://jing-xin.com/en/product/product-29-494.html
[7] https://www.allied-material.co.jp/en/techinfo/hard-metal/process.html
[8] https://www.zgcccarbide.com/news/The-Manufacturing-Process-of-Cemented-Carbide-Inserts:-A-Comprehensive-Guide-39.html
[9] https://www.sanalloy.co.jp/en/cemented_carbide/
[10] https://www.zzsinocarbide.com/faq.html
[11] https://www.everloy-cemented-carbide.com/en/column/782/
[12] https://www.betalentcarbide.com/production-process-of-cemented-carbide-blade.html
[13] https://en.wikipedia.org/wiki/Cemented_carbide
[14] https://tractor.en.made-in-china.com/product/oXExRQFGOmcZ/China-High-Quality-Cemented-Carbide-Mining-Tools-Tungsten-Carbide-Drill-Bits.html
[15] https://www.retopz.com/57-frequently-asked-questions-faqs-about-tungsten-carbide/
[16] https://www.yatechmaterials.com/en/technology/classification-and-use-of-cemented-carbide/
[17] https://www.sanalloy.co.jp/en/q_a/
[18] https://www.bddrillgroup.com/mining-cemented-carbide/tungseten-cemented-carbide-for-dth-bits.html
[19] https://carbideprovider.com/custom-made-cemented-carbide-blanks/
[20] https://www.notoalloy.co.jp/english/product/ccpp.html
[21] https://www.hyperionmt.com/en/Resources/materials/cemented-carbide/
[22] https://www.sciencedirect.com/science/article/pii/B9780128041734000235
[23] https://www.sciencedirect.com/topics/materials-science/cemented-carbide
[24] https://en.csu-pm.com/news/269.html
[25] https://eit.europa.eu/news-events/news/eit-rawmaterials-cobalt-free-solutions-cemented-carbide-tools-and-their-production
[26] https://www.sciencedirect.com/science/article/pii/S026343681830533X
[27] https://www.zgcccarbide.com/news/How-Cemented-Carbide-Tips-Improve-the-Performance-of-Alloys-54.html
[28] https://www.allied-material.co.jp/en/techinfo/hard-metal/use.html
[29] https://en.csu-pm.com/news/333.html
[30] https://en.csu-pm.com/news/339.html
[31] http://www.wococarbide.com/Transaction/article_info/id/1040.html
[32] https://www.linkedin.com/pulse/composition-properties-mining-cemented-carbide-una-song
[33] https://www.zzbetter.com/new/Tungsten-Carbide-Mining-Tools1.html
[34] https://www.zgcccarbide.com/news/China-Cemented-Carbide-Tip:-A-Guide-to-Hard-Alloy-in-the-Metallurgical,-Mining,-and-Energy-Industry-125.html
[35] https://www.nanjingxyc.com/?p=2312
[36] https://www.shutterstock.com/search/cemented-carbide
[37] https://wenlijituan.en.made-in-china.com/product/wEHRoIVChPUr/China-Tungsten-Carbide-Special-Form-Mining-Tool-for-Granite-Mining.html
[38] https://www.bddrillgroup.com/mining-cemented-carbide/chinese-tungsten-carbide-buttons-for-rock.html
[39] https://www.shutterstock.com/search/insert-carbide
[40] https://wenlijituan.en.made-in-china.com/product/VEzYQWUGoHRr/China-K034-Mining-Tip-Tungsten-Carbide-Chisel-Tip-Cemented-Carbide-Tools.html
[41] https://stock.adobe.com/search?k=tungsten+carbide
[42] https://www.alibaba.com/product-detail/Cemented-Carbide-Drill-Bits-For-Geological_1600074854193.html
[43] https://www.shutterstock.com/search/carbide-tipped-tool
[44] https://en.jgcarbide.com
[45] https://www.shutterstock.com/search/tungsten-carbide-tool?image_type=illustration
[46] https://abtdrill.en.made-in-china.com/product/WKOnBDhVLSpH/China-Cemented-Carbide-Drill-Bits-for-Geological-Prospecting-Drilling-Tools.html
[47] https://www.istockphoto.com/photos/carbide-cutter-insert
[48] https://www.ceratizit.com/int/en/company/passion-for-cemented-carbide-/production.html
[49] https://www.acarbide.com/production-process/
[50] https://www.nite.go.jp/data/000007640.pdf
[51] https://www.everloy-cemented-carbide.com/en/process
[52] https://www.mmc-carbide.com/permanent/courses/91/cemented-carbides.html
[53] https://blog.foerstergroup.com/en/component-testing/process-control-for-manufacturing-of-cemented-carbides
[54] https://www.sandvik.coromant.com/en-us/press/celebrating-cemented-carbide
[55] https://www.rydmetcarbide.com/faq/
[56] http://machinetoolrecyclers.com/rita_hayworth.html
[57] https://tuncomfg.com/about/faq/
[58] http://es.carbide-good.com/faq/
[59] https://www.zgcccarbide.com/news/Tungsten-Carbide:-A-Comprehensive-Guide-for-Industry-Professionals-217.html
[60] https://www.everloy-cemented-carbide.com/en/knowledge/faq.html
[61] https://risingstarmaterial.com/applications-of-cemented-carbide/
[62] https://www.yatechmaterials.com/en/cemented-carbide-industry/answers-to-questions-about-the-use-of-tungsten-carbide-edm-blocks/
[63] https://www.tungco.com/insights/blog/frequently-asked-questions-used-tungsten-carbide-inserts/
[64] https://www.carbidetek.com/faqs/
[65] https://www.scmtstool.com/blog/What-Are-the-Industrial-Applications-of_bid-316545588.html
[66] https://www.istockphoto.com/photos/tungsten-carbide-drill-bits
[67] https://www.alamy.com/stock-photo/tungsten-carbide.html
[68] https://www.alamy.com/stock-photo/carbide-insert.html
[69] https://www.traderscity.com/board/productscatalog/cemented-carbide-mining-tools.html
[70] https://patents.google.com/patent/US20160144468A1/en
[71] https://www.rocktechnology.sandvik/siteassets/product-documents/rock-tools/cutting/sandvik_cutting_catalog_2024.pdf
