A New High Wear-resistant Cemented Carbide Optimized for Laser Powder Bed Fusion

Additive Manufacturing (AM) of wear-resistant components is increasingly crucial for the oil and gas and mining industries, where durability under harsh conditions is essential. Traditional additive-manufacturable cemented carbide alloys are limited to a maximum of 65% tungsten carbide (WC), which constrains the wear resistance of the final composite. Enhancing the WC content beyond this threshold is vital for improving component performance and lifespan. Additionally, the conventional cobalt-based binders used are costly and subject to supply chain vulnerabilities. In this study, we present the design and development of a novel cemented carbide alloy optimized for Laser Powder Bed Fusion (LPBF) additive manufacturing. Leveraging advanced computational techniques—including machine learning algorithms, optimization strategies, and multi-scale simulations—we engineered a binder alloy with reduced cobalt content capable of incorporating over 65% WC. The binder is designed to achieve an optimal balance between hardness and ductility and features a narrow liquidus temperature range (~10 K), advantageous for LPBF processing. Analytical and finite element analysis (FEA) models were employed to predict melt pool dimensions and fine-tune LPBF process parameters for optimal manufacturability. Experimental validation, conducted in collaboration with InnoTech Alberta, confirmed successful 3D printability of the designed alloy. Comprehensive material characterization demonstrated its suitability for fabricating complex geometries via LPBF with enhanced wear resistance properties. This advancement represents a significant step forward in the additive manufacturing of cemented carbides, enabling the production of durable, customized components suitable for the demanding environments of the oil and gas and mining sectors. Furthermore, the computational pipeline developed is adaptable and can be applied to other alloy design challenges focused on LPBF, potentially accelerating innovation in the field of additive manufacturing.