Analysis of granulated carbide powder and how it affects pressing

Abstract: During the pressing of powder mixtures to make cemented carbide tools, the degree to which the powder spreads to fill the die and to which it compacts is uncertain. This leads to inconsistent dimensions and densities in the finished product. This performance changes with the composition of the powder, including the amount of pressing agent in the mixture, the particle size distribution and particle shape. One way to quantify the degree to which powder will spread to fill the mold evenly is using the property called 'flowability'. There are several techniques by which flowability can be measured, and each technique does not always give results that are consistent with other techniques. It is, therefore, important to know what technique(s) predict(s) the final behavior of the powder in this application before it is used in quality assurance or to design a process. Additionally, powder size distribution and shape metrics are measured using dynamic image analysis to investigate if there is any relationship between key values of these properties and compaction behavior. In this study, static Angle of repose, Tap Density, Hall flow time and Powder rheometry were benchmarked against each other and against the dimensions of presses and liquid phase sintered tool inserts to understand which technique had the strongest dependence on the compactability, which was defined as the ratio of the tallest dimension in the insert to the smallest. After the study, the results showed that a more extensive particle size distribution improves the compaction properties and that the powders with a higher resistance to a rotating blade tend to have better compaction properties. On the other hand, a clear pattern for the results of all measurement methods and the correlation between the compaction behavior of the carbide tools could not be discerned. In conclusion, the study showed that it is possible to determine a relationship between the results of measurement methods and the compaction behavior of powders. By using simple tests to predict the compactability properties, both money and time can be saved on the research of new, improved powder. Furthermore, the implementation of this study can lead to even better pressing and compactibility properties in the future for cemented carbide tools.