Properties, Advantages, and Prospects of Using Cobalt-Free Composites Based on Tungsten Carbide in Industry

Abstract

This paper reviews recent advances in the synthesis of cobalt-free high-strength tungsten carbide (WC) composites as sustainable alternatives to conventional WC-Co composites. Due to the high cost of cobalt, limited supply, and environmental concerns, researchers are exploring nickel, iron, ceramic binders, and nanocomposites to obtain similar or superior mechanical properties. Various synthesis methods such as powder metallurgy, encapsulation, 3D printing, and spark plasma sintering (SPS) are discussed, with SPS standing out for its effectiveness in densifying and preventing WC grain growth. The results show that cobalt-free composites exhibit high strength, wear and corrosion resistance, and harsh environment stability, making them viable competitors for WC-Co materials. The use of nickel and iron with SPS is shown to enable the development of environmentally friendly, cost-effective materials. It is emphasized that microstructural control and phase management during sintering are critical to improve a material’s properties. The application potential of these composites covers mechanical engineering, metallurgy, oil and gas, and aerospace, emphasizing their broad industrial relevance.