Nickel-Based Tungsten Carbide Composite Powder

GREENSTONE Ni-WC composite powders combine a nickel-based self-fluxing alloy matrix with tungsten carbide hard phases.

Typical WC reinforcement levels include:

5%, 10%, 15%, 20%, 25%, 30%, 40%, 50% and 60% WC, with other carbide ratios available according to application requirements.

For lower and medium WC contents, the nickel matrix provides good metallurgical bonding, corrosion resistance and processability, while WC particles significantly improve abrasive wear resistance.

Higher WC contents are intended for extremely abrasive environments where surface durability is more important than coating ductility.

Typical applications include:

• Oil & gas drilling components
• Mining machinery
• Screw and barrel surfaces
• Pump and valve components
• Agricultural wear parts
• Hydraulic components
• Industrial rollers
• Mechanical seals
• Heavy-duty wear surfaces

Ni-WC Powder for Laser Cladding

For laser cladding applications, GREENSTONE offers nickel-based WC composite powders optimized for controlled powder feeding and stable deposition.

Typical nickel-based matrix hardness ranges from approximately 45–65 HRC, depending on matrix chemistry and WC content.

Laser cladding produces a metallurgically bonded wear-resistant layer with relatively controlled heat input, making the process suitable for both new-component surface enhancement and remanufacturing of worn industrial components.

Ni-WC Powder for PTA Hardfacing

Selected Ni-WC formulations are also suitable for Plasma Transferred Arc (PTA) hardfacing.

High carbide-loading compositions can provide excellent abrasive wear resistance for components operating in contact with sand, minerals, drilling media and other aggressive particulates.

The final coating properties depend on carbide type, carbide morphology, matrix composition, dilution and PTA processing parameters.

Iron-Based TiC Composite Powder

GREENSTONE Fe-TiC composite powders combine an iron-based alloy matrix with titanium carbide reinforcement.

Typical TiC contents include approximately:

20% TiC, 30% TiC and 40% TiC.

TiC provides high hardness and excellent abrasive wear resistance, while the Fe-based matrix can provide favorable metallurgical compatibility with steel substrates.

Depending on the selected matrix, Fe-TiC powders can be designed for:

• Abrasive wear resistance
• Impact and wear resistance
• Surface strengthening
• Corrosion and wear resistance
• Repair of steel components
• Heavy-duty industrial hardfacing

Fe-TiC systems are particularly attractive where an iron-based wear-resistant composite coating is preferred over a nickel-based material.

WC-Co Cemented Carbide Powder

WC-Co is one of the most established cemented carbide systems for industrial wear-resistant coatings.

GREENSTONE can supply WC-Co composite powders including commonly used compositions such as:

WC-10Co-4Cr and WC-12Co.

WC provides extreme hardness and abrasion resistance, while the cobalt-based binder improves cohesion and toughness.

WC-10Co-4Cr additionally benefits from chromium-containing binder chemistry and is widely used where a combination of wear and corrosion resistance is required.

Typical applications include:

• Pump components
• Hydraulic components
• Oil & gas equipment
• Mining components
• Valve components
• Industrial rolls
• Wear sleeves
• Aerospace and energy components
• Erosion-resistant surfaces

These materials are particularly suited to compatible thermal spray processes such as HVOF, subject to the required powder specification.

Cr₃C₂-NiCr Composite Powder

Cr₃C₂-NiCr is a chromium carbide–nickel chromium composite system widely used for wear protection under elevated-temperature conditions.

Compared with conventional WC-based materials, chromium carbide systems can offer better carbide stability at elevated service temperatures.

Typical advantages include:

• High-temperature wear resistance
• Oxidation resistance
• Erosion resistance
• Corrosion resistance
• Thermal stability

Typical applications include boiler components, turbine-related components, process equipment, rolls and other high-temperature wear surfaces.

Composite Powder Manufacturing and Powder Quality

Depending on material system and final application, composite powders may be produced using technologies such as blending, cladding/coating, agglomeration and sintering, crushing, spheroidization or other controlled powder-processing routes.

The appropriate manufacturing route is selected according to the required carbide distribution, particle morphology, apparent density, flowability and deposition process.

GREENSTONE focuses on controlling:

• Chemical composition
• Carbide content
• Particle-size distribution
• Powder uniformity
• Flowability
• Apparent density
• Hard-phase distribution
• Batch consistency

This helps provide reliable feeding behavior and repeatable coating performance.

Key Advantages

• Multiple Ni-WC, Fe-TiC, WC-Co and Cr₃C₂-NiCr composite systems
• Excellent abrasive and erosive wear resistance
• High-hardness carbide reinforcement
• Nickel-, iron- and cobalt-based matrix options
• Suitable for severe industrial wear environments
• Materials available for laser cladding, DED, PTA and thermal spraying
• Carbide content can be optimized for different wear conditions
• Good powder flowability for compatible powder feeding systems
• Suitable for component manufacturing, repair and remanufacturing
• Customized matrix chemistry and particle-size distribution available
• Solutions available for combined wear, corrosion, impact and elevated-temperature exposure