The high-performance tool materials have been inevitably used for most of the cutting tool applications where high reliability and difficult to cut materials are of major demand. The cemented carbides and its composites offer an excellent combination of the properties where it can be used for tool materials due to its high wear resistance, high hardness at elevated temperatures, and considerable fracture toughness. However to obtain optimum values of mechanical properties and uniformly distributed ultrafine grains, a number of new fabrication techniques, alteration in the content of cemented carbide composition, and variation in the parameters of fabrication process have been employed. This review paper will come in handy for researchers and scientists working on advanced cemented carbides and spark plasma sintering as it overviews the recent work done on tungsten carbide composites using the novel spark plasma sintering technique considering different process parameters in order to achieve ultrafine microstructures of sintered specimens, enhanced mechanical properties of composites in addition to energy as well as time saving considerations. The thorough review of various research papers revealed that the parameters of the sintering (sintering temperature, applied pressure, surrounding environment), additives in sintering (both content and composition), reinforcement of cemented carbide with other materials, nano-filler/whisker addition, partial or complete removal of metallic phase from the cemented carbide affect the properties of sintered specimens and their calculated as well as optimum setting can provide an excellent combination of properties desired in cutting tool operations.
QuHXZhuSGLiQ, et al.Influence of sintering temperature and holding time on the densification, phase transformation, microstructure and properties of hot pressing WC-40 vol% Al2O3 composites. Ceram Int2012; 38: 1371–1380.
2.
QuHXZhuSGLiQ, et al.Microstructure and mechanical properties of hot-pressing sintered WC-x vol% Al2O3 composites. Mat Sci Eng A2012; 543: 96–103.
3.
YangFZZhaoJAiX. Effect of initial particulate and sintering temperature on mechanical properties and microstructure of WC-ZrO -VC ceramic composites. J Mater Process Tech2009; 209: 4531–4536.
4.
KatiyarPKSinghPKSinghR, et al.Modes of failure of cemented tungsten carbide tool bits (WC/Co): a study of wear parts. Int J Refract Met Hard Mater2016; 54: 27–38.
5.
YuanYDingJWangY, et al.Optimization of process parameters for fabricating functionally gradient WC–Co composites. Int J Refract Met Hard Mater2014; 43: 109–114.
6.
MukhopadhyayABasuB. Recent developments on WC-based bulk composites. J Mater Sci2010; 46: 571–589.
7.
Cheol KimHShonIJYoonJK, et al.Rapid sintering of ultrafine WC–Ni cermets. Int J Refract Met Hard Mater2005; 24: 427–431.
8.
BiswasKMukhopadhyayABasuB, et al.Densification and microstructure development in spark plasma sintered WC–6 wt% ZrO2 nanocomposites. J Mater Res2011; 22: 1491–1501.
9.
BasuBVenkateswaranTSarkarD. Pressureless sintering and tribological properties of WC–ZrO2 composites. J Eur Ceram Soc2005; 25: 1603–1610.
10.
ImasatoSTokumotoKKitadaT, et al.Properties of ultra-fine grain binderless cemented carbide ‘RCCFN’. Int J Refract Met Hard Mater1995; 13: 305–312.
11.
ZhengDHLiXQLiYY, et al.Zro2 (3Y) toughened WC composites prepared by spark plasma sintering. J Alloy Compd2013; 572: 62–67.
12.
ZhengDHLiXQLiYY, et al.Zirconia-toughened WC with/without VC and Cr3C. Ceram Int2014; 40: 2011–2016.
13.
MalekOLauwersBPerezY, et al.Processing of ultrafine ZrO2 toughened WC composites. J Eur Ceram Soc2009; 29: 3371–3378.
14.
KimHCParkHKJeongIK, et al.Sintering of binderless WC-MoC hard materials by rapid sintering process. Ceram Int2008; 34: 1419–1423.
15.
KimHCKimDKWooKD, et al.Consolidation of binderless WC-TiC by high frequency induction heating sintering. Int J Refract Met Hard Mater2008; 26: 48–54.
OuyangCXZhuSGQuHX. VC And Cr3C doped WC-MgO compacts prepared by hot-pressing sintering. Mater Des2012; 40: 550–555.
18.
OuyangCXZhuSGMaJ, et al.Master sintering curve of nanocomposite WC-MgO powder compacts. J Alloy Compd2012; 518: 27–31.
19.
ZhengDHLiXQAiX, et al.Bulk WC-Al2O3 composites prepared by spark plasma sintering. Int J Refract Met Hard Mater2012; 30: 51–56.
20.
KimHCKimDKWooKD, et al.Consolidation of binderless WC–TiC by high frequency induction heating sintering. Int J Refract Met Hard Mater 2008; 26: 48–54.
21.
BasuBVenkateswaranTSarkarD. Pressureless sintering and tribological properties of WC–ZrO2 composites. J Eur Ceram Soc2005; 25: 1603–1610.
22.
CaoTLiXLiJ, et al.Effect of sintering temperature on phase constitution and mechanical properties of WC-1.0 wt% carbon nanotube composites. Ceram Int2018; 44: 164–169.
23.
BaiTXieT. Fabrication and mechanical properties of WC-Al2O3 cemented carbide reinforced by CNTs. Mater Chem Phys2017; 201: 113–119.
24.
AhmadIYazdaniBZhuY. Recent advances on carbon nanotubes and graphene reinforced ceramics nanocomposites. Nanomaterials2015; 5: 90–114.
25.
WalkerLSMarottoVRRafieeMA, et al.Toughening in graphene ceramic composites. ACS Nano2011; 5: 3182–3190.
26.
DuszaJMorgielJDuszováA, et al.Microstructure and fracture toughness of Si3N4+graphene platelet composites. J Eur Ceram Soc2012; 32: 3389–3397.
27.
PorwalHTatarkoPGrassoS, et al.Graphene reinforced alumina nano-composites. Carbon N Y2013; 64: 359–369.
28.
CentenoARochaVGAlonsoB, et al.Graphene for tough and electroconductive alumina ceramics. J Eur Ceram Soc2013; 33: 3201–3210.
ChenY-FBiJ-QYinC-L, et al.Microstructure and fracture toughness of graphene nanosheets/alumina composites. Ceram Int2014; 40: 13883–13889.
31.
AhmadIIslamMAbdoHS, et al.Toughening mechanisms and mechanical properties of graphene nanosheet reinforced alumina. Mater Des2015; 88: 1234–1243.
32.
AhmadIIslamMAlharthiNH, et al.Chemical and structural analyses of the graphene nanosheet/alumina ceramic interfacial region in rapidly consolidated ceramic nanocomposites. J Compos Mater2017; 52: 417–428.
33.
WuWGuiJSaiW, et al.The reinforcing effect of graphene nano-platelets on the cryogenic mechanical properties of GNPs/Al2O3 composites. J Alloys Compd2017; 691: 778–785.
34.
LiZZhaoJSunJ, et al.Reinforcement of Al2O3/TiC ceramic tool material by multi-layer graphene. Ceram Int2017; 43: 11421–11427.
35.
NietoALahiriDAgarwalA. Graphene nanoplatelets reinforced tantalum carbide consolidated by spark plasma sintering. Mater Sci Eng2013; A582: 338–346.
36.
PetrusMCyganJWTAdamcyzk-cieslakB, et al.Sintering behavior of silicon nitride matrix composite reinforced with multilayer graphene. Ceram Int2017; 43: 5007–5013.
37.
ParidaaSPJenabPC. An overview: different manufacturing techniques used for fabricating functionally graded material. Mater Today: Proc2019; 18: 2942–2951.
38.
EttmayerPKolaskaHOrtnerHM. 1.01 – history of hardmetals. In: SarinVK (ed) Comprehensive hard materials. Oxford: Elsevier, 2014, pp.3–27.
39.
WeiCSongXZhaoS, et al.In-situ synthesis of WC–Co composite powder and densification by sinter-HIP. Int J Refract Met Hard Mater2010; 28: 567–571.
40.
KornausKRaczkaMGubernatA, et al.Pressureless sintering of binderless tungsten carbide. J Eur Ceram Soc2017; 37: 4567–4576.
41.
FangZZWangXRyuT. Synthesis, sintering, and mechanical properties of nanocrystalline cemented tungsten carbide—a review. Int J Refract Met Hard Mater2009; 27: 288–299.
42.
ZhangPShenWYanLI. Effect of thermal shock on mechanical properties of dispersion strengthened tungsten with nano-TaC by SPS. Hot Work Technol2012; 41: 88–91.
43.
JiaCSunLTangH. Hot pressing of nanometer WC–Co powder. Int J Refract Met Hard Mater2007; 25: 53–56.
44.
LinHSunJLiC. A facile route to synthesize WC–Co nanocomposite powders and properties of sintered bulk. J Alloy Compd2016; 682: 531–536.
45.
ZhangXZhuSDingH, et al.Fabrication and properties of hot-pressing sintered WC-Al2O3 composites reinforced by graphene platelets. Int J Refract Met Hard Mater2019; 82: 81–90.
46.
BaiTXieT. Fabrication and mechanical properties of WC- Al2O3 cemented carbide reinforced by CNTs. Mater Chem Phys2017; 201: 113–119.
47.
BrevalEChengJPAgrawalDK. Comparison between microwave and conventional sintering of WC/Co composites. Mater Sci Eng A2005; 391: 285–295.
48.
SunilBRSivaprahasamDSubasriR. Microwave sintering of nanocrystalline WC–12Co: challenges and perspectives. Int J Refract Met Hard Mater2010; 28: 180–186.
49.
BaoRJian-HongYIPengYD. Effects of microwave sintering temperature and soaking time on microstructure of WC–8Co. Trans Nonferr Met Soc China2013; 23: 372–376.
50.
ZhaoSXSongXYZhangJX. Effects of scale combination and contact condition of raw powders on SPS sintered near-nanocrystalline WC-Co alloy. Mater Sci Eng A2008; 473: 323–329.
51.
ChaSIHongSHKimBK. Spark plasma sintering behavior of nanocrystalline WC–10Co cemented carbide powders. Mater Sci Eng A2003; 351: 31–38.
52.
HuangSGVanmeenselKLiL. Tailored sintering of VC-doped WC–Co cemented carbides by pulsed electric current sintering. Int J Refract Met Hard Mater2008; 26: 256–262. Spark plasma sintering, Int. J. Refract. Hard Met. 38 (2013) 7–14.
53.
SunLJiaCCaoR. Effects of CrC additions on the densification, grain growth and properties of ultrafine WC–11Co composites by spark plasma sintering. Int J Refract Met Hard Mater2008; 26: 357–361.
54.
VermaVKumarBVM. Sliding wear behavior of SPS processed TaC-containing Ti(CN)-WC-Ni/Co cermets against silicon carbide. Wear2017; 376: 1570–1579.
55.
SivaprahasamDChandrasekarSBSundaresanR. Microstructure and mechanical properties of nanocrystalline WC–12 Co consolidated by spark plasma sintering. Int J Ref Met Hard Mater2007; 25: 144–152.
56.
MengFLiuCZhangF, et al.Densification and mechanical properties of fine-grained Al2O3 -ZrO2 composites consolidated by spark plasma sintering. J Alloys Compd2012; 512: 63–67.
57.
Rodriguez-SuarezTBartoloméJFSmirnovA, et al.Sliding wear behavior of alumina/nickel nanocomposites processed by a conventional sintering route. J Eur Ceram Soc2011; 31: 1389–1395.
58.
SunLYangTEJiaCC, et al.VC, Cr 3C 2 doped ultrafine WC–Co cemented carbides prepared by spark plasma sintering. Int J Refract Met Hard Mater2011; 29: 147–152.
59.
BiswasKHeJQBlumID, et al.High-performance bulk thermoelectrics with all-scale hierarchical architectures. Nature2012; 489: 414–418.
60.
LiuYFLiebenbergDH. Electromagnetic radio frequency heating in the pulsed electric current sintering (PECS) process. MRS Commu2017; 7: 266–271.
61.
FuJBrouwerJCRichardsonIM, et al.Effect of mechanical alloying and spark plasma sintering on the microstructure and mechanical properties of ODS Eurofer. Mater Des2019; 177: 107849.
62.
CramerCLMcMurrayJWLanceMJ, et al.Reaction-bond composite synthesis of SiC-TiB2 by spark plasma sintering/ field-assisted sintering technology (SPS/FAST). J Eur Ceram Soc2020; 40: 988–995.
63.
WestonNSThomasBJacksonM. Processing metal powders via field assisted sintering technology (FAST): a critical review. Mater Sci Technol2019; 35: 1306–1328.
64.
GanHWangCBShenQ, et al.Preparation of La2NiMnO6 double perovskite ceramics by plasma activated sintering. J Inorg Mater2019; 34: 541–545.
65.
AlanizJEDupuyADKoderaY, et al.Effects of applied pressure on the densification rates in current-activated pressure-assisted densification (CAPAD) of nanocrystalline materials. Scr Mater2014; 92: 7–10.
66.
ShenZJZhaoZPengH, et al.Formation of tough interlocking microstructures in silicon nitride ceramics by dynamic ripening. Nature2002; 417: 266–269.
67.
HuZ-YZhangZ-HChengX-W, et al.A review of multi-physical fields induced phenomena and effects in spark plasma sintering: fundamentals and applications. Mater Des2020; 191: 108662.
68.
IgeOOAriboSObadeleBA, et al.Erosion–corrosion behaviour of spark plasma sintered WC - 12Co in aggressive media. Int J Refract Met Hard Mater2017; 66: 36–43.
69.
GhasaliEEbadzadehTAlizadehM, et al.Unexpected SiC nanowires growth during spark plasma sintering of WC-10Si: a comparative study on phase formation and microstructure properties against WC-10Co cermet. J Alloys Compd2019; 786: 938–952.
70.
LiuKWangZYinZ, et al.Effect of Co content on microstructure and mechanical properties of ultrafine grained WC-Co cemented carbide sintered by spark plasma sintering. Ceram Int2018; 44: 18711–18718.
71.
SuWZouJSunL. Effects of nano-alumina on mechanical properties and wear resistance of WC-8Co cemented carbide by spark plasma sintering. Int J Refract Met Hard Mater2020; 92: 105337.
72.
FaziliANikzadLRahimiPourMR, et al.Effect of Al2O3 ceramic binder on mechanical and microstructure properties of spark plasma sintered WC-Co cermets. Int J Refract Met Hard Mater2017; 69: 189–195.
73.
SongXLiuXZhangJ. Neck formation and self-adjusting mechanism of neck growth of conducting powders in spark plasma sintering. J Am Ceram Soc2006; 89: 494–500.
74.
WangLZhangJJiangW. Recent development in reactive synthesis of nanostructured bulk materials by spark plasma sintering. Int J Refract Met Hard Mater2013; 39: 103–112.
75.
SahebNIqbalZKhalilA, et al. Spark plasma sintering of metals and metal matrix nanocomposites: a review. J Nanomater2012; 2012: 1–13.
76.
ZhangZHLiuZFLuJF, et al.The sintering mechanism in spark plasma sinteringProof of the occurrence of spark discharge. Scr Mater2014; 81: 56–59.
77.
HulbertDMAndersAAnderssonJ, et al.A discussion on the absence of plasma in spark plasma sintering. Scr Mater2009; 60: 835–838.
78.
DengXCincaNGarbiecD, et al.Wear resistance of nanostructured Cr-based WC hardmetals sintered by spark plasma sintering. Int J Refract Met Hard Mater2020; 86: 105092.
79.
ZhouHWangZWangB. Fabrication of WC-Co/(Ti, W)C graded cemented carbide by spark plasma sintering. Int J Refract Met Hard Mater2020; 87: 105141.
80.
WangZYuBLiuK, et al.Performance and wear mechanism of spark plasma sintered WC-based ultrafine cemented carbides tools in dry turning of Ti–6Al–4V. Ceram Int2020; 46: 20207–20214.
81.
QinY-QPengY-QTianY, et al.Effect of Y2O3 on microstructure and mechanical properties of WC-Co cemented carbides prepared via solid-liquid doping method and spark plasma sintering. Mater Today Commun2020; 24: 101096.
82.
ZhangMDupuyADLiJ, et al.High temperature compressive properties and microstructure of WC Ni3Al cermets prepared by spark plasma sintering. Vacuum2020; 175: 109281.
83.
BiswasMSarkarSHalderR, et al.Sintering and characterization of a hard-to-hard configured composite: spark plasma sintered WC reinforced α SiAlON. J Phys Chem Solids2020; 145: 109548.
84.
RosaJMBLugonRDde Souza SilvaK, et al.Study of characteristics and properties of spark plasma sintered WC with the use of alternative Fe-Ni-Nb binder as Co replacement. Int J Refract Met Hard Mater2020; 92: 105316.
85.
ChangLJiangYWangW, et al.Ultrafine WC-0.5Co-xTaC cemented carbides prepared by spark plasma sintering. Int J Refract Met Hard Mater2019; 84: 104994.
86.
LuoWLiuYShenJ. Effects of binders on the microstructures and mechanical properties of ultrafine WC-10%AlxCoCrCuFeNi composites by spark plasma sintering. J Alloys Compd2019; 791: 540–549.
CaoTLiXLiJ, et al.Effects of sintering temperature on phase constitution and mechanical properties of WC-1.0 wt% carbon nanotube composites. Ceram Int2018; 44: 164–169.
89.
YadhukkulakrishnanGBRahmanAKarumuriS, et al.Spark plasma sintering of silicon carbide and multiwalled carbon nanotube reinforced zirconium diboride ceramic composite. Mater Sci Eng A2012; 552: 125–133.
90.
ZhangHAWuHJGuSY. Preparation and properties of MoSi2 based composites reinforced by carbon nanotubes. Ceram Int2013; 39: 7401–7405.
91.
LiuXMYinXWZhengGP, et al.In-situ formation of carbon nanotubes in pyrolytic carbon-silicon nitride composite ceramics. Ceram Int2014; 40: 531–540.
92.
YavasBSahinFYucelO, et al.Effect of particle size, heating rate and CNT addition on densification, microstructure and mechanical properties of B4C ceramics. Ceram Int2015; 41: 8936–8944.
93.
KasperskiAWeibelAAlkattanD, et al.Doublewalled carbon nanotube/zirconia composites: preparation by spark plasma sintering, electrical conductivity and mechanical properties. Ceram Int2015; 41: 13731–13738.
94.
VasudevanSKothariASheldonBW. Direct observation of toughening and R-curve behavior in carbon nanotube reinforced silicon nitride. Scr Mater2016; 124: 112–116.
95.
AslMSFarahbakhshINayebiB. Characteristics of multi-walled carbon nano- tube toughened ZrB2 -SiC ceramic composite prepared by hot pressing. Ceram Int2016; 42: 1950–1958.
96.
NisarAAriharanSVenkateswaranT, et al.Effects of carbon nanotube on processing, microstructural, mechanical and ablation behavior of ZrB2 −20SiC ultra-high temperature ceramic composites. Carbon N Y2017; 111: 269–282.
97.
HanJJSuDZhaoZH, et al.Fabrication and toughening behavior of carbon nanotube (CNT) scaffold reinforced SiBCN ceramic composites with high CNT loading. Ceram Int2017; 43: 9024–9031.
98.
LinJYangYHZhangHA, et al.Effects of CNTs content on the microstructure and mechanical properties of spark plasma sintered TiB2-SiC ceramics. Ceram Int2017; 43: 1284–1289.
99.
JinHMengSHXieWH, et al.HfB2 -CNTs composites with enhanced mechanical properties prepared by spark plasma sintering. Ceram Int2017; 43: 2170–2173.
100.
ZuYFShaJJLiJ, et al.Effect of multiwalled carbon nanotubes on microstructure and fracture properties of carbon fibre reinforced ZrB2-based ceramic composite. Ceram Int2017; 43: 7454–7460.
101.
PoetschkeJRichterVHolkeR. Influence and effectivity of VC and Cr3C2 grain growth inhibitors on sintering of binderless tungsten carbide. Int J Refract Met Hard Mater2012; 31: 218–233.
102.
RajaeiHFarviziMMobasherpourI, et al.Effect of spark plasma sintering temperature on microstructure and mechanical properties of mullite – WC composites. Int J Refract Met Hard Mater2018; 70: 197–201.
103.
TangWZhangLZhuJ-f, et al.Effect of direct current patterns on densification and mechanical properties of binderless tungsten carbides fabricated by the spark plasma sintering system. Int J Refract Met Hard Mater2017; 64: 90–97.
104.
XiaXLiXLiJ, et al.Microstructure and characterization of WC-2.8 wt% Al2O3-6.8 wt% ZrO2 composites produced by spark plasma sintering. Ceram Int2016; 42: 14182–14188.
105.
ChenW-HLinH-TChenJ, et al.Microstructure and wear behavior of spark plasma sintering sintered Al2O3/WC-based composite. Int J Refract Met Hard Mater2016; 54: 279–283.
106.
ChenW-HLinH-TNayakPK, et al.Sintering behavior and mechanical properties of WC–Al2O3 prepared by spark plasma sintering (SPS)composites. Int J Refract Met Hard Mater2015; 48: 414–417.
107.
RummanMRXieZHongS-J, et al.Effect of spark plasma sintering pressure on mechanical properties of WC–7.5 wt% nano Co. Mater Des2015; 68: 221–227.
LangaTOlubambiPShabalalaT, et al.Densification and structural transformation during spark plasma sintering of WC-Co-YSZ-cBN systems. Int J Refract Met Hard Mater2018; 72: 341–348.
110.
ChaSIHongSHKimBK. Spark plasma sintering behavior of nanocrystalline WC-10Co cemented carbide powders. Mater Sci Eng2003; 351: 31–38.
111.
SongXGaoYLiuX, et al.Effect of interfacial characteristics on toughness of nanocrystalline cemented carbides. Acta Mater2013; 61: 2154–2162.
112.
YangQYangJWenY, et al.A novel route for the synthesis of ultrafine WC-15 wt%Co cemented carbides. J Alloy Comp2018; 748: 577–582.
113.
SunLYangTJiaC, et al.VC, Cr3C doped ultrafine WC-Co cemented carbides prepared by spark plasma sintering. Int J Refract Met Hard Mater2011; 29: 147–152.
114.
TraceyVA. Nickel in hardmetals. Int J Refract Met Hard Mater1992; 11: 137–149.
115.
SchubertWDFuggerMWittmannB, et al.Aspects of sintering of cemented carbides with Fe-based binders. Int J Refract Met Hard Mater2015; 49: 110–123.
116.
TarrasteMKübarseppJJuhaniK, et al.Ferritic chromium steel as binder metal for WC cemented carbides. Int J Refract Met Hard Mater2018; 73: 183–191.
117.
RaihanuzzamanRMXieZHongSJ, et al.Powder refinement, consolidation and mechanical properties of cemented carbides- An overview. Powder Technol2014; 61: 1–13.
118.
FangZZWangXRyuT, et al.Synthesis, sintering, and mechanical properties of nanocrystalline cemented tungsten carbide-A review. Int J Refract Met Hard Mater2009; 27: 288–299.
