Rapid consolidation of nanostuctured WC-FeAl₃ by pulsed current activated heating and its mechanical properties

In the case of cemented WC, Ni or Co is added as a binder for the formation of composite structures. However, the high cost of Ni or Co, the low hardness and the low corrosion resistance of the WC-Ni and WC-Co cermets have generated interest in recent years for alternative binder phases. In this study, FeAl₃ was used as a novel binder and consolidated by the pulsed current activated sintering (PCAS) method. Highly dense WC-FeAl₃ with a relative density of up to 97% was obtained within 2 min by PCAS under a pressure of 80 MPa. The average grain sizes of the sintered WC and WC-FeAl₃ were lower than 100 nm. The addition of FeAl₃ to WC enhanced the mechanical properties and increase of relative density.