Toward Greener Synthesis of WC Powders for Cemented Tungsten Carbides Manufacturing

Tungsten carbide (WC) is the most important tungsten compound, and the main component of WC-Co cermet composites. WC-Co are widely used engineering materials due to the combination of high hardness and strength of tungsten carbide with the toughness and plasticity of the metallic binder. The direct synthesis of WC from tungsten concentrate containing ∼70% WO₃ has been achieved by carbothermic reduction. Mineral/carbon black mixtures were prepared by planetary ball milling and subjected to annealing at 1150 °C in flowing Ar. Specific leaching treatments have been developed to remove foreign phases and obtain pure WC powders. This new process allows about 50% energy saving, −34% CO₂ emissions, and significantly lower amounts of industrial waste, with respect to the classical hydrometallurgical tungsten extraction and subsequent pyrometallurgical WC synthesis, widely used in tungsten industry. WC powders obtained by carbothermic reduction of the mineral were employed to prepare sintered WC-8 wt %Co samples that showed high density (>99%), hardness (1490 HV), and toughness (14.6 MPa·m^1/2). These findings demonstrate, for the first time, that the carbothermic reduction of tungsten concentrates does represent a viable process for energy efficient and sustainable synthesis of WC powders to be used in the production of cemented carbides.