Papers by Author: Koenraad Bonny

Abstract: At present, cobalt is the most commonly used binder material in tungsten carbide based hardmetals. Current research on sliding wear performance of these cemented carbides, however, reveals promising results for nickel binder as well. Test samples of WC-Co and WC-Ni hardmetals have been machined and surface finished by wire-EDM and grinding. From comparative dry sliding pin-on-plate experiments on wire-EDM’ed, ground and polished grades, correlations are derived between wear volume loss and friction on the one hand and contact pressure, sliding distance, binder phase and microstructure on the other hand. The lowest wear levels are encountered with polished cemented carbides. The EDM induced surface modification turns out to deteriorate wear resistance, especially during the running-in stage of sliding. These findings are in agreement with Xray diffraction measurements of the residual stress level in the WC phase.

Abstract: WC-Co based cemented carbides are widely used in technical applications, in which they are exposed to complex thermo-mechanical loadings. Previous research work has demonstrated that these materials exhibit a lifetime-limiting fatigue sensitivity at room temperature. This investigation is focused on the influence of heating as a result of friction of pin-on-plate tribocouples. WC-Co samples have been manufactured and surface finished by wire-EDM and grinding. Reciprocative dry friction experiments are performed under various loading conditions and sliding velocities. Correlations are established between the bulk temperature rise of the test samples and the imposed test conditions, material properties, surface conditions and coefficient of friction. Topographies and cross-section views of the tested samples were examined by SEM, revealing temperature dependent wear mechanisms, including binder phase modification.

Abstract: Zirconia-based ceramic composites such as ZrO2-WC, ZrO2-TiCN and ZrO2-TiN, are suitable for wire-EDM, due to their sufficiently electro-conductive secondary phases inside. Thus, the material removal technique of EDM to shape complex geometry materials economically and with high accuracy, irrespective of mechanical properties, could be successfully employed on these ceramics. Samples of these ZrO2-based ceramics were developed in laboratory and manufactured and surface finished by wire-EDM. Reciprocative dry sliding pin-on-plate experiments revealed that the ZrO2-WC composite exhibits better tribological characteristics in comparison with the composites of ZrO2-TiCN and ZrO2-TiN. Furthermore, topographies and cross-sectional views of worn surfaces were analyzed by SEM, revealing that the secondary phase inside the investigated composites governs the wear mechanism.

Abstract: Tungsten carbide based hardmetals with cobalt binder phase are widely used in engineering industries for their excellent mechanical properties and outstanding wear performance. Reciprocative sliding wear behaviour of a number of WC-Co based hardmetal grades was investigated using a small-scale pin-on-plate tribometer. Test samples were manufactured by electro-discharge machining (EDM) with various surface finishing regimes. SEM topographies and cross-section views of the cemented carbides were obtained both before and after dry friction tests, revealing distinctive wear mechanisms. The generated wear loss was quantified topographically using surface scanning equipment. Wear debris particles were collected and examined by EDX and TEM analysis. Based on experimental results, the execution of consecutive gradually finer EDM cutting steps was found to considerably enhance wear performance. Furthermore, a significant influence of contact load, sliding movement duration, application of lubricant and wear debris formation on wear rate and friction was established.

Abstract: A trend in the development of WC based cemented carbides and zirconia based ceramic composites is grain size refinement and more narrow grain size distributions of the starting powder, in order to accomplish higher hardness and abrasive wear resistance. The current work reports the results of dry sliding wear experiments on laboratory-made electrically conductive ZrO2-WC composites and commercially available WC-Co based cemented carbides, which have been manufactured and finished by rough cutting wire EDM with consecutive execution of gradually finer EDM regimes. Tribological data are obtained using a small-scale pin-on-plate test rig. Wear tracks are analyzed by surface scanning topography and scanning electron microscopy, revealing that the outer extensions of the wear tracks exhibit some differences in wear behavior compared to the central parts.