Effect of direct current patterns on densification and mechanical properties of binderless tungsten carbides fabricated by the spark plasma sintering system

Binderless tungsten carbide materials (bWCs) were fabricated by the spark plasma sintering (SPS) system. Ultrafine WC powders with adjusted oxygen contents and C/W atomic ratios were used as raw materials. Constant and pulsed direct current patterns (constant DC and pulsed DC) were chosen as the power supplies. The results indicate that for WC starting powders with either low (0.31%) or high (0.95%) oxygen contents, a relative density larger than 99.0% can be reached by pulsed DC at 1820 °C. Nevertheless, the severely oxidized WC powders cannot be well-densified by constant DC. A high degree of densification of bWCs facilitates the collaborative improvement of the toughness and hardness. The existence of W₂C facilitates the improvement of the hardness at the high expense of the toughness. The existence of graphite phase is substantially detriment to the toughness. The grain coarsening facilitates the improvement of the toughness with sacrificed hardness. The related mechanism is discussed.