Scientists just 3D printed one of the hardest metals on Earth

Tungsten carbide-cobalt (WC-Co) is a highly durable material prized for its ability to resist wear, pressure, and repeated use. This makes it an ideal choice for industrial tools, but its manufacturing process is both costly and wasteful. Researchers have now utilized additive manufacturing (AM), also known as 3D printing, to create WC-Co cemented carbide, potentially reducing waste and production costs while preserving the material's exceptional strength and hardness.

WC-Co cemented carbides are commonly used in cutting tools, drills, machining equipment, and construction tools, and are produced primarily through a process called powder metallurgy, which involves compressing and heating fine tungsten carbide and cobalt powders. This study, published in the International Journal of Refractory Metals and Hard Materials, explored whether AM could provide a more efficient alternative to conventional manufacturing methods.

Using a technique called laser hot-wire welding, the researchers were able to deposit WC-Co cemented carbide only where it was needed, rather than shaping the material by cutting away excess or filling a mold. This process reduced material usage and energy consumption while maintaining the material's hardness and mechanical integrity.

The findings demonstrate that additive manufacturing can produce defect-free, industrial-grade cemented carbide with a hardness above 1400 HV, placing it among the toughest materials used in industry. While there are still challenges to overcome, such as reducing cracking and improving durability, this new method has the potential to revolutionize the production of extremely hard materials, making advanced tools more economical while preserving their exceptional properties.