Effect of WC Particle Size on Microstructure and Mechanical Properties of WC‐10CoCrFeNiAl Composites

The present study focuses on the synthesis of three distinct WC‐HEA hard alloys using the SPS method, using three different grades of tungsten carbide with varying particle sizes. Subsequently, an investigation is conducted to analyze the influence of WC particle size on the microstructure and properties of WC‐10CoCrFeNiAl hard alloys. Additionally, an investigation was conducted to assess the influence of small particle size WC addition content on both the microstructure and properties of this advanced alloy. The results indicate that a reduction in the particle size of WC leads to an increase in hardness, while exhibiting a nonmonotonic change in fracture toughness of WC‐10CoCrFeNiAl hard alloy. The presence of smaller WC particles promotes the formation of N₇C₃ and η phase (M₃W₉C₄), which compromises its toughness while simultaneously enhancing its hardness. The mechanical properties are optimized when the particle size of WC is ≈1 μm. The incorporation of fine WC particles significantly enhances hardness while compromising fracture toughness. When the content of small particle WC reaches 25 wt%, the mechanical properties of the dual‐scale hard alloy are optimized, the hardness and fracture toughness are 18.8 GPa and 11.1 MPa.m^1/2, respectively.