Evaluation of spheroidized tungsten carbide powder produced by induction plasma melting

Abstract

SYNOPSIS Tungsten carbide is a fine grey powder. It can be formed into shapes by compacting with the addition of a binder. Spherical particles are generally preferred in additive manufacturing as they pack together more efficiently than non-spherical particles, promoting a uniform powder bed density, better flowability, and elimination of internal cavities and fractures, resulting in a better quality of final product. The particle shape of powders can be transformed into spherical through the process of spheroidization. However, due to its high melting point, tungsten carbide could be difficult to spheroidize. Tungsten carbide was spheroidized using an inductively coupled radio frequency plasma at various plate powers between 9 and 15 kW. The influence of additional H2 in the sheath gas on the chemical composition of the tungsten carbide product was also investigated by means of XRD, which indicated that WC is converted to W2C at higher H2 concentrations. Optical analysis of SEM micrographs indicated that the spheroidization ratio increased with increased plasma energy. Keywords: spheroidization, induction plasma melting, tungsten carbide.

The Effects of Induction Plasma Spheroidization on the Properties of Yttrium-Stabilized Zirconia Powders and the Performance of Corresponding Thermal Barrier Coatings for Gas Turbine Engine Applications

“…The droplets then rapidly solidify into spherical powders with enhanced properties [18][19][20]. Through the use of the IPS technology, the structure of ceramic powders can also be controlled to achieve specific structures and properties [21][22][23]. Current research in this area is ongoing, but there is a scarcity of studies on the effect of the IPS treatment on the microstructure and properties of YSZ powders used in thermal barrier coatings.…”