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<p>Five cemented carbide nanocomposites containing 10 wt% Ni, 2.5 wt% nano-Al₂O₃, and varying graphene Platelets (GPNs) ratios (0.3, 0.6, 0.9 wt%) were fabricated using powder metallurgy. The WC-Al₂O₃/x GNPs powders were mixed for 6 h, followed by electroless nickel coating with hydrazine as a reducing agent. The fabricated nanocomposites were evaluated for relative density, microstructure, hardness, wear resistance, thermal conductivity, and corrosion resistance. Results showed a relative density of 94% for the WC/10 wt% Ni composite, which slightly decreased with the addition of alumina and graphene. Microstructural analysis revealed uniform graphene distribution and strong adhesion within the matrix. Nickel and graphene additions improved toughness, while no cracks were observed in hardness tests. The incorporation of 0.3 wt% GNs significantly increased hardness to 930.2 HV, while 0.9 wt% GNs achieved the highest hardness of 1175.48 HV. Tribological tests indicated the lowest wear rate (1.8 mg/min) and coefficient of friction (0.0033) for the sample with 0.9 wt% GNs. Additionally, graphene and alumina enhanced heat dissipation from the cutting zone during wear testing. The 0.9 wt% GNs sample reduced the cutting zone temperature from 62.6 °C (WC/10Ni) to 31.9 °C, showcasing superior thermal performance and stability over extended operation. Furthermore, graphene additions enhanced corrosion resistance, with the 0.9 wt% GNs sample achieving the lowest corrosion rate (0.56399 mm/year). These results suggest that the developed nanocomposites are highly suitable for advanced cutting tool applications, offering improved durability, thermal efficiency, and overall performance.</p>

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Enhanced mechanical, tribological, and thermal properties of (WC-Ni–Al₂O₃/x GNPs) nanocomposites for advanced cutting tool applications

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年7月29日

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  • Hossam M. Yehia,
  • Omayma A. El-Kady,
  • Taysser M. Mahmoud,
  • Mohamed Elmahdy

摘要

Five cemented carbide nanocomposites containing 10 wt% Ni, 2.5 wt% nano-Al₂O₃, and varying graphene Platelets (GPNs) ratios (0.3, 0.6, 0.9 wt%) were fabricated using powder metallurgy. The WC-Al₂O₃/x GNPs powders were mixed for 6 h, followed by electroless nickel coating with hydrazine as a reducing agent. The fabricated nanocomposites were evaluated for relative density, microstructure, hardness, wear resistance, thermal conductivity, and corrosion resistance. Results showed a relative density of 94% for the WC/10 wt% Ni composite, which slightly decreased with the addition of alumina and graphene. Microstructural analysis revealed uniform graphene distribution and strong adhesion within the matrix. Nickel and graphene additions improved toughness, while no cracks were observed in hardness tests. The incorporation of 0.3 wt% GNs significantly increased hardness to 930.2 HV, while 0.9 wt% GNs achieved the highest hardness of 1175.48 HV. Tribological tests indicated the lowest wear rate (1.8 mg/min) and coefficient of friction (0.0033) for the sample with 0.9 wt% GNs. Additionally, graphene and alumina enhanced heat dissipation from the cutting zone during wear testing. The 0.9 wt% GNs sample reduced the cutting zone temperature from 62.6 °C (WC/10Ni) to 31.9 °C, showcasing superior thermal performance and stability over extended operation. Furthermore, graphene additions enhanced corrosion resistance, with the 0.9 wt% GNs sample achieving the lowest corrosion rate (0.56399 mm/year). These results suggest that the developed nanocomposites are highly suitable for advanced cutting tool applications, offering improved durability, thermal efficiency, and overall performance.