Tungsten carbide buttons are popular mining tools used for drilling, mining, digging, and so on. Do you know how the tungsten carbide buttons are used?
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What is tungsten carbide?
Tungsten carbide, also known as cemented carbide, is composed of refractory metal, and binder metal. Tungsten carbide powder is a gray powder, with a very high melting point, which makes it difficult to be melted like other metal powder. So the common method to manufacture tungsten carbide products in industries is powder metallurgy. From tungsten carbide powder to the final tungsten carbide products, they become harder and more wear resistant.
What are tungsten carbide buttons?
Tungsten carbide buttons are one of the tungsten carbide products used for mining, oil, and gas. Tungsten carbide buttons have high hardness, strength, wear resistance, and corrosion resistance, which make them suitable for the mining industry. Tungsten carbide buttons for different drill bits and machines can be of different grades and shapes. The most common grades are YG8. And they can be made into tungsten carbide conical buttons, parabolic buttons, ball buttons, spoon buttons, wedge buttons, and so on.
Manufacturing of tungsten carbide buttons
Tungsten carbide buttons are manufactured from tungsten carbide powder and cobalt powder in different proportions. Tungsten carbide powder and cobalt powder should be mixed in a certain proportion and be milled in the ball milling machine. After around 24 hours of milling, the mixture should get dried, and then compacted according to drawings. Sintering is the most important process in powder metallurgy. During this process, the temperature will increase slowly, and the green tungsten carbide buttons will shrink. After that, quality checking is necessary.
How to insert tungsten carbide buttons?
Tungsten carbide buttons can be inserted into drill bits directly, like taper drill bits, and can also be inserted into a shank bit first, then installed on the machine. In modern industry, there are two kinds of methods to insert tungsten carbide buttons into drill bits. They are hot forging and cold pressing.
Cold pressing is also applied when workers insert cemented carbide button inserts into a drill bit directly, which demands button teeth a little bit larger than the holes of drill bits but must strictly follow the field limit of the drill bits. Workers need to prepare cemented carbide button inserts and drill bits. Then, put the cemented carbide button inserts above the hole and press an external force, which can be achieved by human power or a machine.
This process is also easy to operate and highly efficient. But it has strict demand for the tolerance of cemented carbide button tips; otherwise, it will be easily flawed. This method has its disadvantages. The service life of the production will be limited, and the buttons are easy to lose or break during their work. So workers prefer to use this method to deal with products with low requirements.
Hot forging is a common way to insert tungsten carbide buttons into a drill under a high temperature. Hot forging can be applied to insert into drill bits or shank bits. Firstly, workers should prepare tungsten carbide buttons, drill bits, flux paste, and alloy steel. Flux paste uses to wet the copper alloy and help to forge the tungsten carbide buttons into the drill bits. Then, heat the copper steel at a high temperature to melt. At this moment, it is easier for tungsten carbide button bits to insert into the holes. Hot forging is easy to operate but asks for high temperatures. In this way, tungsten carbide button tips and the drill bits are less damaged and have better stability. So workers deal with products with high requirements in this way.
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When we are inserting tungsten carbide buttons into shank bits, for better quality, we can clad a layer of cermet, do heat treatment, and blast.
Shank bits can be installed into different machines, one example is the road header machine.
Road header machine has powerful cutting heads so it is worldwide popular for coal mining, non-metallic minerals mining, and boring tunnel. Although a road header machine is large, it can still perform flexibility during transport tunnels, rehabilitation of existing tunnels, and excavation of underground caverns. A road header machine consists of a crawler traveling mechanism, cutting heads, shovel plate, loader gathering arm, and conveyor. Cutting heads included many tungsten carbide buttons, which are inserted in a helical way. They make a great effect during the machine’s working. The cutting heads of the road header can be equipped with. One is the transverse cutting head, and the other is the longitudinal cutting head.
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Tungsten carbide is one of the most worldwide materials used in industry. The carbide button is made from tungsten carbide, so it has the properties of cemented carbide. The cylinder shape of tungsten carbide button bits makes it easy to insert into other tools by heat inlaying and cold pressing. Because carbide button inserts hold the properties of hardness, toughness, and durability, it is common to see them in various situations like well drilling, rock milling, road operation, and mining event. But how is the carbide button made? In this article, we will figure out this question.
The following process will be produced:
1. Raw Material Preparation
2. Powder Mixing
3. Wet Milling
4. Spray Drying
5. Pressing
6. Sintering
7. Quality check
1. Raw Material Preparation
The following procedures need the materials WC powder and Cobalt powder. WC powder is made of tungsten ores, mined and fined in nature. Tungsten ores will experience a range of chemical reactions, first with oxygen to become tungsten oxide and then with carbon to become WC powder.
2. Powder Mixing
Now here is the first step how factories make carbide teeth. Factories will add some binders (Cobalt powder or Nickel powder) in WC powder. Binders are just like the “glue” in our daily life to help combine tungsten carbide more tightly. Workers must test the mixed powder to ensure it can utilize in the following steps.
3. Wet Milling
During this procedure, the mixing powder will be put into a Ball Milling Machine and milled with liquid like water and ethanol. This liquid will not react chemically but facilitates grinding.
4. Spray Drying
This procedure always happens in a dryer. But different factories may choose different kinds of machines. The following two types of machines are common. One is Vacuum Dryer; the other is Spray Drying Tower. They have their advantages. Spray drying work with high heat and inert gases to evaporate the water. It can evaporate most of the water, which does better to the following two procedures Pressing and Sintering. Vacuum Drying does not need that high temperature but is expensive and costs a lot to maintain.
5. Pressing
To press powder into different shapes that customers need, workers will make a mold first. Carbide buttons come in different shapes so you can see different types of dies, with a conical head, ball head, parabolic head, or spoon head, with one or two chamfers, and with or without pinholes. There are two shaping ways. For the small size of buttons, workers will press them by an automatic machine; for larger ones, workers will press them by a hydraulic pressing machine.
6. Sintering
Workers will put pressed carbide bit tips on a graphite plate and in the Hot Isostatic Pressing (HIP) Sintered Furnace under a temperature of about 1400˚ C. The temperature must be raised at a low speed so that the carbide button shrinks slowly and the finished button has better performance. After sintering, it will shrink and only have nearly half as much volume as before.
7. Quality check
Quality checks are very important. Carbide inserts are first checked for properties such as hardness, cobalt magnetic, and microstructure to check for holes or small cracks. A micrometer should be used to check its size, height, and diameter before packing.
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