Carbide vs Tungsten Carbide: Key Differences Explained
Carbide and tungsten carbide are among the most widely utilized materials in modern industry. Both of these materials are found in cutting tools, moulds, mining equipment components, and other wear-and-tear parts; yet, many get one idea mixed up with the other, “carbide” mistaken for “tungsten carbide”. Below we offer a complete overview of carbide vs tungsten carbide from all aspects. Let’s begin!
Part 1. What is Carbide?
Carbide is a generic chemical term applied to refer to compounds formed when carbon atoms combine with metal or metalloid elements, normally by combining with one another. Each form of carbide possesses unique features and applications depending on its composition and crystal form. They are normally very hard, possess very high melting points, exhibit good chemical stability, and possess wonderful wear resistance making them priceless both in industrial procedures as well as within research laboratory environments.
Common carbides are:
- Tungsten Carbide (WC)
- Calcium Carbide (CaC₂)
- Silicon Carbide (SiC)
- Titanium carbide (TiC),
- Niobium carbide (NbC),
- Vanadium carbide (VC)
- …
Carbide is not a specific chemical compound, but an overall group of compounds. Among them, tungsten carbide (WC) is the most costly and widely used in commercial production.
Part 2. What is Tungsten Carbide?
Tungsten Carbide (WC) is the most important and versatile member of carbide family consisting of tungsten (W) and carbon (C) atoms with a strong chemical bond between each other. It is a perfect hard material and the principal ingredient of cemented carbide. Tungsten carbide powder, in fact, is usually sintered along with metal binders such as cobalt (Co) or nickel (Ni) to produce a composite material with high hardness and adequate toughness.
Key Features of Tungsten Carbide
Unaffected Hardness
Tungsten carbide is harder than almost all metal and alloy materials and only below cubic boron nitride (cBN) and diamond. Its Vickers hardness is generally between 1600–2000 HV. This renders it an ideal material to be used in cutting tools and wear parts.
Excellent Wear Resistance
Components constructed of tungsten carbide are tens of times longer-lasting than components constructed of common steels, thus it is widely used in equipment used for mining, petroleum drilling equipment, and metalworking cutters where maximum durability is required.
High Melting Point and Thermal Stability
Having a melting point of around 2870°C, tungsten carbide is extremely stable in both physical and chemical form even at very high temperatures, making it well-suited for high-speed cutting and heavy-duty machining.
High Density
Having a density of about 15.6 g/cm³, just below that of gold and significantly higher than most metals, provides it with especially good application in situations where a great deal of mass is required and shock is necessary, such as in armor-piercing bullets and high-precision counterweights.
Excellent Chemical Stability
It is highly resistant to corrosion by all but the most aggressive acids and alkalis and can thus be employed to operate reliably in hostile environments.
Tungsten carbide has become virtually synonymous with “hard material” because of its superior hardness, wear resistance, and thermal stability and has earned a vital place in industrial production and niche applications.
Part 3. Manufacturing Process Comparison: Carbide vs Tungsten Carbide
Different carbides have different processes of production, which affect their uses and their properties directly.
1. Silicon Carbide (SiC)
Silicon carbide is usually made using a high-temperature electric furnace process. The raw material is carbon (coke or petroleum coke) and quartz (SiO₂), which react at about 2000°C:
SiO2+3C→SiC+2CO↑
This process allows for mass production of SiC crystals. The silicon carbide obtained is very hard, has good thermal conductivity, and wear resistance, and thus it is widely used as abrasives, ceramic, and semiconductor at high temperatures.
2. Calcium Carbide (CaC₂)
Calcium carbide is produced by the electric arc furnace process. Limestone (CaCO₃) and coke are the raw materials and react at high temperatures (around 2000°C) to produce:
CaO+3C→CaC2+CO↑
Calcium carbide is used chiefly as a raw chemical feedstock. When calcium carbide reacts with water, it gives off acetylene gas (C₂H₂), which is used in welding and chemical synthesis.
3. Tungsten Carbide (WC)
The production of tungsten carbide is more complex and involves commonly the powder metallurgy process:
Preparation of Raw Material: Pure tungsten powder is mixed with carbon black uniformly.
Carburization: In a vacuum or inert atmosphere at high temperatures (approximately 1400–1600°C), tungsten reacts with carbon to form tungsten carbide powder.
Sintering and Forming: The tungsten carbide powder is mixed with a metallic binder material (cobalt or nickel), pressed at high pressure, and then sintered at high temperature to form a hard, dense composite.
This reaction produces tungsten carbide of very high hardness and significant toughness. Varying the cobalt or nickel content enables manufacturers to find a balance between hardness and toughness:
- Higher cobalt creates higher toughness, suitable for impact-resistant materials.
- Lower cobalt creates higher hardness, suitable for precision cutting tools.
Process Comparison Summary
General carbides (SiC and CaC₂) rely primarily on high-temperature chemical reactions, suitable for large-scale raw material production.
Tungsten carbide, on the other hand, is manufactured through powder metallurgy with a metal binder, and the products that are obtained have high hardness, strength, and wear resistance, for which reason it is applied in cutting tools, wear parts, and molds.
Part 4. Comparison of Performance: Carbide and Tungsten Carbide
| Property | Carbide (General) | Tungsten Carbide (WC) |
| Definition | A broad category of compounds formed by carbon and metals or metalloids, including SiC, CaC₂, TiC, etc. | A specific compound of tungsten and carbon, forming the core material of cemented carbide. |
| Hardness | Varies by type: SiC is extremely hard, while CaC₂ is relatively soft. | Extremely high, close to diamond, with Vickers hardness around 1600–2000 HV, suitable for wear-resistant applications. |
| Melting Point | Varies: e.g., SiC ~2730°C, CaC₂ ~2000°C | About 2870°C, maintaining stability under high-temperature conditions. |
| Density | Varies widely, from lightweight materials like SiC to heavier carbide powders. | Approximately 15.6 g/cm³, higher than most metals, suitable for applications requiring high density. |
| Common Applications | Chemical raw materials (CaC₂), abrasives, ceramics, electronic devices (SiC), etc. | High-hardness cutting tools, molds, drill bits, wear-resistant components, as well as jewelry and precision counterweights. |
| Cost | Generally lower, suitable for large-scale production. | Relatively high, but offers exceptional performance for high-end industrial and precision manufacturing. |
In terms of performance, general carbides vary in composition and character and are usually used as raw material or for special application. Tungsten carbide is characterized by its extreme hardness, resistance to wear, and thermal stability and is the preferred material for cutting tools and high-wear components. The material selection finally depends on the requirements of the application for hardness, wear resistance, density, and cost.
Part 5. Advantages and Limitations of Carbide vs Tungsten Carbide
When choosing material for industrial application, it is important to know the strengths and weaknesses of general carbides and tungsten carbide. Both share some strengths and weaknesses depending on the application, cost, and required performance.
Carbide (General)
General carbides are a family of carbon-metal or carbon-metalloid materials. They are affordable, versatile, and used in a broad range of industries.
Advantages
- Range of materials: Includes SiC, CaC₂, TiC, VC, and so on to select depending on specific performance criteria.
- Wide applications: Used in the production of chemicals, abrasives, ceramics, electronics, and semiconductors.
- Relatively cheap: Most carbides are easy to produce on a large scale, and thus economically competitive.
Limitations
- Large difference in properties: Hardness, toughness, melting point, and resistance to wear vary extensively across different carbides.
- Limited strength and toughness: Some carbides, like CaC₂, are not suitable for high-impact or heavy-load uses.
- Processing challenges: More challenging carbides require special equipment and procedures for machining or cutting.
Tungsten Carbide (WC)
Tungsten carbide is a high-strength specialty carbide that’s famous for exceptional hardness, wear resistance, and heat stability.
Advantages
- Very hard: Nearing diamond, which makes it ideal for high-strength cutting tools and wear components.
- High wear resistance: Lasts several times longer than common steels under heavy-duty applications.
- High thermal stability: Steady melting point (~2870°C) and chemical stability allow for use in harsh environments.
- Toughness and strength that can be varied: Binder content can be controlled to tailor hardness and toughness to specific applications.
Limitations
- Costly: Raw materials and processing are complex, causing overall cost to increase.
- Difficult to process: Very high hardness requires specialized equipment for cutting, forming, and polishing.
- Relatively heavy: At a density of ~15.6 g/cm³, it will not be suited for light applications.
General carbides are used in cost-saving and general-purpose uses, while tungsten carbide should be applied to high-end cutting tools, wear components, and molds due to its increased hardness, durability, and heat stability. The selection is dependent on performance requirement, cost, and processing constraints.
Part 6. Tungsten Carbide vs Carbide: Which One Should You Choose
General carbides or tungsten carbide must be chosen according to your application requirements, i.e., wear resistance, heat resistance, mechanical stability, and price.
General Carbides:
Versatile and cost-effective, suitable for chemical raw materials, abrasives, ceramics, and electronics. Best when extreme hardness or density is not required.
Tungsten Carbide (WC):
Extremely hard, wear-resistant, and heat-stable. Suitable for cutting tools, drills, molds, and heavy industry applications.
Key Considerations:
Select based on wear vs heat resistance, mechanical load, cost, and weight. In short, general carbides are well-suited for multi-purpose or chemical use, while tungsten carbide is more suitable for high-performance, high-wear industrial use.
FAQs on Carbide vs Tungsten Carbide
1. Is carbide heavier than tungsten?
Not always. The weight is variable with the type of carbide. Tungsten carbide, for example, is around 15.6 g/cm³, which is quite a bit more than pure tungsten (around 19.3 g/cm³), but silicon carbide or calcium carbide are much lighter. So, the weight is variable depending on the specific carbide material.
2. Will a magnet stick to tungsten carbide?
Tungsten carbide is typically not magnetic because it is a ceramic-type material. Commercial tungsten carbide products typically contain cobalt mixed into them as a binder, however, which is slightly magnetic. Thus, a magnet can stick to some tungsten carbide pieces weakly, depending on how much cobalt they contain.
3. Will tungsten carbide tarnish?
Tungsten carbide itself is very stable and will not corrode or oxidize easily, and therefore does not occur naturally as green. Poor quality tungsten carbide with high cobalt content or exposed to certain chemicals can, however, discolor. Well-made tungsten carbide remains gray-silver and resistant to corrosion.
4. How to check if it’s real tungsten carbide?
You can identify genuine tungsten carbide by its hardness that cannot be measured, extreme weight, and metallic-gray appearance. Testing is the scratch test (it readily scratches glass or steel), magnet test (slightly magnetic due to cobalt binder), and checking its weight, tungsten carbide is much heavier than most metal of the same size. The certified vendors generally provide a chemical composition or a hardness test report to ensure authenticity.
Bottom Line
Carbide is a generic term that refers to a family of metal-carbon or metalloid-carbon products, but tungsten carbide is the material of choice for high performance applications. Other materials may also be utilized as carbides, but if it’s cutting tools, molds, and wear-resistant industrial components one is involved with, then tungsten carbide is much superior to others.
If you require high-performance cemented carbide tools or parts, tungsten carbide is an ideal choice. As a professional manufacturer of tungsten carbide parts, XYMJ offers an impressive selection of high-quality tungsten carbide parts with the mission to meet the demands of modern industry.
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