WIRE MEMBER OF CEMENTED CARBIDE BASED ON TUNGSTEN CARBIDE

Abstract: A wire member of cemented carbide based on tungsten carbide contains a binder phase of 4 to 35 % by weight of at least one metal selected from the group consisting of cobalt and nickel, 1 to 50 ppm by weight of unavoidable impurities and a hard dispersed phase of balance tungsten carbide. The tungsten carbide has an average particle size ranging from 0.2 to 1 µm. A particle size of the impurities is not larger than 10 µm. The distance between an axis of the wire member and a point on a periphery of the wire member disposed farthest from the axis of the wire member is 0.025 to 1 mm. The wire member may contain a binder phase of 15 to 35 % by weight of at least one metal selected from the group consisting of cobalt and nickel, 1 to 50 ppm by weight of unavoidable impurities, and a hard dispersed phase consisting of 0.1 to 40 % by weight of at least one compound selected from the group consisting of carbides of metals in Groups IV A , V A and VI A of the Periodic Table other than tungsten, nitrides of metals in Groups IV A and V A of the Periodic Table and solid solution of at least two of the carbides and nitrides, and balance tungsten carbide. The hard dispersed phase also has an average particle size of 0.2 to 1 µm.

Description: BACKGROUND OF THE INVENTION Field of the Invention The present invention pertains to a wire member of cemented carbide, based on tungsten carbide (WC), which is excellent in toughness and wear resistance. Printing wires comprising tungsten carbide are described, for example, in EP-A-148 613. Prior Art Heretofore, a print pin of a dot printer, for instance, has been made of a wire member of WC-based cemented carbide since high wear resistance is required. Such a conventional wire member includes a hard dispersed phase composed of tungsten carbide and a binder phase composed of 4 to 20 % by weight of one or two metals of cobalt and nickel. In some cases, the hard dispersed phase of such a wire member further contains 0.1 to 40 % by weight of one or more of compounds selected from the group consisting of carbides of metals in Groups IV A , V A and VI A of the Periodic Table other than tungsten, nitrides of metals in Groups IV A and V A of the Periodic Table and solid solution of two or more of these carbides and nitrides. For producing such a wire member of WC-based cemented carbide, powders for forming the above binder and hard dispersed phases are first prepared and matched in prescribed compositions. Thereafter, the matched powders are mixed with a solvent and a lubricant, and molded by an extruder or the like into a green compact of a shape of a round bar. Then, the green compact is presintered, and subsequently sintered at a temperature of 1,350 to 1,500°C to provide a sintered compact of a round bar. Finally, the outer periphery of the sintered compact is ground by a centerless grinder or the like to produce a wire member of a prescribed outer diameter. Although the prior art wire member of WC-based cemented carbide as mentioned above has been superior in wear resistance, it has been inferior in toughness, thereby being susceptible to breakage in actual use. This has been especially the case with apparatuses developed in recent years wherein requirements for such a wire member are getting severe in order to achieve a higher speed operation as well as a higher performance. SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a wire member of cemented carbide, based on tungsten carbide, which exhibits not only high wear resistance but excellent toughness as well. According to a first aspect of the present invention, there is provided a wire member of cemented carbide, based on tungsten carbide, containing a binder phase of 4 to 35 % by weight of at least one metal selected from the group consisting of cobalt and nickel, 1 to 50 ppm by weight of unavoidable impurities, and a hard dispersed phase of balance tungsten carbide, an average particle size of the hard dispersed phase being 0.2 to 1 µm, a particle size of the impurities being not larger than 10 µm, the distance between an axis of the wire member and a point on a periphery of the wire member disposed farthest from the axis of the wire member being 0.025 to 1 mm. According to a second aspect of the present invention, there is provided a wire member of cemented carbide, based on tungsten carbide, containing a binder phase of 4 to 35 % by weight of at least one metal selected from the group consisting of cobalt and nickel, 1 to 50 ppm by weight of unavoidable impurities, and a hard dispersed phase of 0.1 to 40 % by weight of at least one compound and balance tungsten carbide, the at least one compound being selected from the group consisting of carbides of metals in Groups IV A , V A and VI A of the Periodic Table other than tungsten, nitrides of metals in Groups IV A and V A of the Periodic Table and solid solution of at least two of the carbides and nitrides, an average particle size of the hard dispersed phase being 0.2 to 1 µm, a particle size of the impurities being not larger than 10 µm, the distance between an axis of the wire member and a point on a periphery of the wire member disposed farthest from the axis of the wire member being 0.025 to 1 mm. DESCRIPTION OF THE INVENTION It has been found that the hard dispersed phase of the prior art wire member as described above has an average particle size ranging from 1.5 to 5 µm, and that unavoidable impurities are present in the member in the content of 100 ppm by weight. In addition, the majority of the impurities have an average particle size fallen within a range of 15 to 45 µm. The inventors have made an extensive study over the improvement if such a prior art wire member, and have obtained a wire member in accordance with the present invention which includes a binder phase of 4 to 35 % by weight of at least one metal selected from the group consisting of cobalt and nickel, 1 to 50 ppm by weight of unavoidable impurities, and a hard dispersed phase of balance tungsten carbide, an average particle size of the hard dispersed phase being 0.2 to 1 µm, a particle size of the impurities being not larger than 10 µm, the wire member having a diameter of 0.05 to 2 mm. In the wire member in accordance with the present invention, the average particle size of the hard dispersed phase and the content of the unavoidable impurities are respectively reduced substantially, and besides the impurities of a large particle size exceeding 10 µm are avoided. With this construction, the wire member exhibits high toughness as a certain tough metal exhibits. As a result, the wire member can be bent at a radius of curvature satisfying the following relationship: (15 to 50) × (diameter of wire member) In the foregoing, if the content of the binder phase is less than 4 % by weight, the wire member fails to have sufficient toughness. On the other hand, if the content of the binder phase exceeds 35 % by weight, the wire member becomes less resistant to wear. In order to obtain a wire member having higher toughness, the impurities had better be avoided, and besides it is favorable to make a particle size of the tungsten carbide as small as possible. Due to the difficulties in the manufacture, however, a wire member having a hard dispersed phase of an average particle size smaller than 0.2 µm and impurities of the content less than 1 ppm by weight cannot be obtained. On the other hand, if the average particle size of the hard dispersed phase and the content of the impurities exceed 1 µm and 50 ppm by weight, respectively, the wire member fails to exhibit a sufficiently high toughness. Also, the impurities of a particle size in excess of 10 µm deteriorates the toughness, too. Further, in order to increase wear resistance, at least one compound selected from the group consisting of carbides of metals in Groups IV A , V A and VI A of the Periodic Table except tungsten, nitrides of metals in Groups IV A and V A of the Periodic Table and solid solution of two or more of the above carbides and nitrides may be contained in the hard dispersed phase. In such a case, the amount of the compound to be added should range from 0.1 to 40 % by weight. If the amount is less than 0.1 % by weight, no increase in wear resistance can be expected practically. On the other hand, the hard dispersed phase in excess of 40 % by weight adversely affects the toughness of the wire member. In order to obtain a wire member having higher toughness, the average particle size of the compound to be added in the hard dispersed phase should also range from 0.2 to 1 µm, as is the case with the average particle size of the tungsten carbide. Further, the wire member in accordance with the present invention is produced by a conventional process as described above. The inventors, however, have unexpectedly found that if a sintered compact is subjected to hot plastic working such as hot drawing, hot rolling with grooved rolls, hot forging and the like prior to grinding, the wire member thus obtained exhibits higher toughness than the wire member produced without being hot-worked. In such a case, however, the content of the binder phase has to be within a range of 15 to 35 % by weight, and such a binder phase as to have a hot-worked microstructure of an average crystal grain size of 5 to 400 µm has to be obtained. It has been found that a wire member of a diameter of 0.05 to 2 mm thus obtained can be bent at a reduced radius of curvature of the following relationship: (10 to 40) × (diameter of wire member) Further, the wire member as described above has a circular cross-section of a diameter of 0.05 to 2 mm. It, however, may have a regular polygonal cross-section. In such a case, the distance between an axis of the wire member and a point on a periphery of the wire member disposed farthest from the axis of the wire member, i.e., an equivalent radius of the wire member should be within the range of 0.025 to 1 mm. The invention will now be described in more detail with reference to the following examples. Example 1 There were prepared powders for forming a hard dispersed phase having a purity of 99.98 % by weight and an average particle size of 0.2 to 1 µm, and powders of a binder phase having a purity of 99.99 % by weight and an average particle size of 1.5 µm. These powders were matched in blend compositions set forth in Table 1 and a small quantity of paraffin was added as a lubricant to the matched powders. Thereafter, the powders were mixed in an ethanol solvent by an attrition mill for 6 hours, and then were extruded at a pressure of 5 to 20 Kg/mm² to form green compacts having a circular cross-section of various outer diameters. Subsequently, the compacts were subjected to presintering at a temperature of 400 to 600°C for a period of 1 hour to completely remove the above lubricant. The steps from the mixing to the presintering were carried out in a clean room to prevent impurities from getting mixed in the materials. Subsequently, the presintered bars were sintered in a vacuum at a temperature of 1350 to 1500°C for a period of 30 minutes, and finally ground by a centerless grinder to provide wire members 1 to 10 in accordance with the present invention each having such an outer diameter as set forth in Table 1. For comparison purposes, comparative wire members 1 to 10 were prepared according to the above procedure except that powders having a purity of 99.5 to 99.9 % by weight and an average particle size of 1.5 to 5 µm were prepared as powder materials for forming the binder and hard dispersed phases, and that the steps from the mixing to the presintering were carried out in normal surroundings, i.e., in an ordinary room. The comparative wire members are shown in Table 2. Subsequently, the wire members of the invention and the comparative wire members were tested as to the average particle sizes of the hard dispersed phase, the content of the impurities and the maximum particle size of the impurities. In addition, in order to evaluate the wear resistance of the wire members, Vickers hardness was measured, and besides in order to evaluate the toughness, a critical radius of curvature at which each wire member was broken when subjected to bending by 360° was measured. The results obtained are shown in Tables 1 and 2. As clearly seen from Tables 1 and 2, the wire members 1 to 10 in accordance with the present invention exhibited as high hardness as the comparative wire members 1 to 10 did. In addition, each of the wire members in accordance with the present invention exhibited excellent toughness to such an extent that it could be bent at a considerably small radius of curvature. In contrast, all the comparative wire members 1 to 10 were broken when they were bent into an arcuate shape. Example 2 The same powders as those in Example 1 were prepared and mixed in blend compositions as set forth in Table 3, and the same method as that in Example 1 was repeated to provide sintered compacts. Then, the sintered compacts were subjected to hot drawing under the conditions as shown in Table 3, and finally ground to provide wire members 11 to 21 in accordance with the present invention each having an outer diameter as shown in Table 3. For comparison purposes, comparative wire members 11 to 21 were prepared according to the above procedure except that powders having a purity of 99.5 to 99.9 % by weight were prepared as powder material, that the steps from the mixing to the presintering were carried out in normal surroundings, i.e., in an ordinary room, and that the sintered compacts were not subjected to hot drawing. The comparative wire members 11 to 21 are shown in Table 4. Subsequently, the wire members of the invention and the comparative wire members were tested as to the average crystal grain size of the binder phase, the average particle size of the hard dispersed phase, the content of the impurities and the maximum size of the impurities. In addition, in order to evaluate the wear resistance of the wire members, Vickers hardness was measured, and besides in order to evaluate the toughness, a critical radius of curvature at which each wire member was broken when subjected to bending by 360° was measured. The results obtained are shown in Tables 5 and 6. As seen from Tables 5 and 6, the wire members 11 to 21 in accordance with the present invention exhibited as high hardness as the comparative wire members 11 to 21 did. In addition, each of the wire members in accordance with the present invention exhibited excellent toughness to such an extent that it could be bent at a considerably small radius of curvature. In contrast, all the comparative wire members 11 to 21 were broken when they were bent into an arcuate shape. As described above, a wire member of WC-based cemented carbide in accordance with the present invention has not only high wear resistance but also such excellent toughness that the wire member can be bent at a remarkably small radius of curvature into a circular shape. Consequently, such a wire member can be employed for example as a dot pin of a dot printer which requires high wear resistance and toughness, and suitably employed even in an apparatus of high performance operated at high speed.

Claims: A wire member of cemented carbide, based on tungsten carbide, containing a binder phase of 4 to 35% by weight of at least one metal selected from cobalt and nickel; 1 to 50 ppm by weight of unavoidable impurities; and a hard dispersed phase based On tungsten carbide the distance between the long axis of the wire member and a point on a periphery of the wire member disposed farthest from the axis of the wire member being 0.025 to 1 mm; wherein the average particle size of the tungsten carbide is from 0.2 to 1 µm, and any particle which forms part of the impurities being not larger than 10 µm. A wire member as claimed in claim 1, having a circular cross-section. A wire member as claimed in claim 1, having a regular polygonal cross-section. A wire member as claimed in any one of the preceding claims, wherein the hard dispersed phase contains from 0.1 to 40% by weight of at least one compound being selected from carbides of metals in Groups IV A , V A and VI A of the Periodic Table, nitrides of metals in Groups IV A and V A of the Periodic Table and solid solution of at least two of said carbides and nitrides, the average particle size of said selected compound in said hard dispersed phase being from 0.2 to 1 µm. A wire member as claimed in any one of the preceding claims, in which said binder phase contains from 15 to 35% by weight of at least one of cobalt and nickel, the binder phase having a hot-worked microstructure of an average crystal grain size of 5 to 400 µm. A wire member as claimed in claim 5, obtainable by a process comprising the steps of: a) preparing a powder of at least one metal selected from cobalt and nickel, and a powder of tungsten carbide; b) blending said powders so that the content of said at least one metal falls within the range of 15 to 35% by weight; c) forming the blended powders into a green compact; d) sintering the green compact at a prescribed temperature to provide a sintered bar; e) subsequently subjecting the sintered bar to hot working to provide a wire member blank having a hot-worked microstructure of an average crystal grain size of 5 to 400 µm, and f) subsequently grinding the wire member blank to provide said wire member. A wire member as claimed in claim 5, as dependent on claim 4, and obtainable by a process comprising the steps of: a) preparing a powder of at least one metal selected from cobalt and nickel, a powder of at least one compound selected from carbides of metals in Groups IV A , V A and VI A of the Periodic Table other than tungsten, nitrides of metals in Groups IV A and V A of the Periodic Table and solid solution of at least two of said carbides and nitrides, and a powder of tungsten carbide; b) blending said powders so that the content of said at least one metal falls within the range of 15 to 35% by weight and that the content of said at least one compound falls within the range of 0.1 to 40% by weight; c) forming the blended powders into a green compact; d) sintering the green compact at a prescribed temperature to provide a sintered bar; e) subsequently subjecting the sintered bar to hot working to provide a wire member blank having a hot-worked microstructure of an average crystal grain size of 5 to 400 µm; and f) subsequently grinding the wire member blank to provide said wire member. A wire member as claimed in claim 6 or 7, in which said hot working is hot drawing. A wire member as claimed in claim 6 or 7, in which said hot working is hot rolling. A method of making cemented carbide wire having a diameter of from 0.05 to 2 mm, and characterised by the step of formulating the wire from: i) a binder phase of at least one of cobalt and nickel, making up from 4 to 35 weight% of the wire; ii) a hard dispersed phase comprising tungsten carbide, the average plarticle size of the dispersed phase being in a range of from 0.2 to 1 µm; iii) from 1 to 50 ppm (by weight) of unavoidable impurities, with an absence of any impurity particle larger than 10 µm.

Inventors: KAINUMA, TADAHI, SHIMADA, FUMIO
Applicants: MITSUBISHI MATERIALS CORPORATION
Application year: 1987
Main classification: B41J2
IPC codes: B41J2, C22C29