Russian scientists develop ultra-durable tungsten carbide material for industrial tools

MOSCOW, 8 April (BelTA - TV BRICS) - Researchers from the Far Eastern Federal University and the Khabarovsk Federal Research Centre of the Far Eastern Branch of the Russian Academy of Sciences have introduced a new method for producing ultra-strong tungsten carbide, significantly improving the durability of industrial tools.

According to the official website of the Ministry of Science and Higher Education of the Russian Federation, the newly developed material demonstrates wear resistance up to 26 times greater than conventional hard alloys widely used in drilling and machining equipment. Scientists say its application could substantially extend the service life of drills, machine tools, and other components operating under extreme conditions.

For more than a century, tungsten carbide-based alloys have formed the backbone of high-strength industrial tools. These materials typically rely on cobalt as a binding element, which provides toughness but remains vulnerable to abrasion. Over time, this binding phase deteriorates, causing carbide grains to lose structural support and leading to rapid wear.

The research team addressed this limitation by eliminating cobalt entirely and creating a monolithic structure composed of pure tungsten carbide. Using spark plasma sintering, they compressed nanoparticles - around 1,000 times thinner than a human hair - into a dense material with a measured density of 99.94 per cent. The process involved heating to temperatures of up to 2,000°C.

According to the researchers, the resulting material combines greater hardness with lower production costs compared to existing industrial alloys. Laboratory testing confirmed its performance under micro-abrasive conditions, where samples were exposed to particles of varying sizes and hardness.

The new material consistently outperformed traditional alloys, showing significantly lower wear rates. In contrast to standard materials, the size of abrasive particles had minimal impact on its durability.

Scientists highlight a wide range of potential applications, including drilling equipment for the energy and mining sectors, precision components such as bearings operating without lubrication, and pump parts used to handle abrasive fluids containing sand or cement. The absence of cobalt also reduces reliance on a costly and scarce metal.

Further research will focus on optimising the material’s internal structure, including grain size and density, with the aim of preparing it for large-scale industrial use.