Combined Approach to the Synthesis of WC-(Fe, Ni) Hard Alloys: Mechanical Activation and Spark Plasma Sintering

This paper presents a combined approach to the synthesis of WC-(Fe, Ni) hard alloys obtained by mechanical activation and spark plasma sintering (SPS). The main attention at this stage of the work is paid to studying the evolution of the morphology and phase composition of WC-(Fe, Ni) powder mixtures during high-energy milling and their subsequent sintering by the SPS method. The study analyzed the effect of the mechanosynthesis time and the binder phase content on the change in the average particle size, the degree of defect formation, and the phase composition of the powders. It was found that an increase in the milling time to 240 min promotes the formation of the WC nanocrystalline structure and the accumulation of microdefects, which is accompanied by a decrease in the average particle size and an increase in the dislocation density. The X-ray phase analysis of the samples after SPS confirmed the preservation of the WC phase and the formation of the γ-(Fe, Ni) matrix without the formation of secondary carbide phases. The analysis of sample shrinkage showed three main stages: initial compaction, intense shrinkage, and structure stabilization. The obtained data demonstrate that optimization of the parameters of mechanical activation and SPS allow for effective control of the phase composition and morphology of WC-(Fe, Ni) powders, which opens up opportunities for their subsequent study in conditions of aggressive environments and radiation exposure.