Comparative Study of Binder-Free Equimolar WC-TiC and WC-TiC-TaC Ceramics Consolidated by HEBM and SPS

This comparative study investigates binder-free binary WC-TiC and ternary WC-TiC-TaC carbide ceramics as alternatives to cobalt-bonded hard materials. Equimolar compositions were processed via high-energy ball milling (HEBM) and consolidated by spark plasma sintering (SPS) at 1700–2100 °C. X-ray diffraction analysis (XRD) revealed fundamentally different homogenization kinetics: the ternary system achieved a complete single-phase structure at 2000 °C, 100 °C earlier than the binary system. This acceleration correlates with finer initial particle size (2–5 μm vs. 3–10 μm) and near-stoichiometric TaC, facilitating interdiffusion. Lattice parameter evolution confirmed the formation of (W,Ti)C and (W,Ti,Ta)C substitutional solid solutions. Mechanical characterization showed contrasting behaviors: binary WC-TiC exhibits maximum hardness at 1900 °C (1793 HV30, fracture toughness 5.07 MPa·m1/2), while ternary WC-TiC-TaC peaks at 1700–1800 °C (1947–1782 HV30) with higher toughness (max 5.42 MPa·m1/2). Optimal processing windows with acceptable property uniformity are 1800–1900 °C (binary) and 1700–1900 °C (ternary). The binary system offers superior toughness and stability; the ternary system enables faster processing and higher initial hardness, defining distinct application domains.