SiC whisker toughened WC-Al2O3-ZrO2 binderless cemented carbides via fast-hot-pressed sintering and DFT calculations

Binderless cemented carbide has garnered attention for its exceptional hardness and suitability in extreme service conditions. The absence of a metal binder, however, leads to inadequate fracture toughness, which limits its broader application. This study explores the influence of SiC whisker on the microstructure and mechanical properties of WC-Al2O3-ZrO2 binderless cemented carbide, utilizing a combination of experimental method and Density Functional Theory (DFT) calculations. The inclusion of 1 wt.% SiC whisker resulted in a notable increase in fracture toughness, reaching an impressive toughness of , while maintaining a high Vickers hardness of 19.4 GPa. DFT calculations provided insights into the interface energy, cohesive energy, and charge density differences at the WC/SiC interface. This work also presents two models depicting the behavior of whiskers during fracture, based on the observed microstructure and computational findings. Overall, the present work offers significant insights and practical guidance for advancing binderless cemented carbide technologies.