High-end raw materials for cemented carbide are independently supplied, and the -teeth- of the industrial machine are stronger

On a fully automated servo press, robotic arms dance rhythmically as gray-black powder is pressed into form, transforming into blade-like pieces the size of a fingernail in under a second. This is the world of CNC tools, often referred to as the “teeth” of industrial machines. The micro-drills can be as thin as 0.01 millimeters, capable of “embroidering” 56 Chinese characters onto a grain of rice, while the drilling tools can be as wide as a tire, capable of boring through soft soil and hard rock, used in domestically manufactured massive shield machines like the “Momentum No. 1”.

The power within these small tools is remarkable. Their hardness—only second to diamonds—comes from carbide, known for its durability like “iron teeth and copper gums.” In industrial manufacturing, tools are consumables; they must be hard enough to withstand wear, strong enough to avoid breaking, and resilient enough to resist impact. Compared to traditional steel tools, carbide tools cut seven times faster and have a lifespan nearly 80 times longer.

What makes carbide so “indestructible”? The answer lies in the raw material: tungsten carbide powder. “Just like the quality of coffee grounds directly impacts the taste of the coffee, the quality of tungsten carbide powder largely determines the performance of carbide products,” explains Zhou Peng, Deputy General Manager of China Tungsten High-Tech.

Finer grain sizes of tungsten carbide powder correlate with higher hardness, strength, and wear resistance. The tighter the bond between the binder and the tungsten carbide, the more stable the material becomes. However, if the grain size is too small, it can reduce toughness, thermal conductivity, and mechanical strength, increasing processing difficulties. “The most challenging part is precisely controlling the technical specifications and process details,” Zhou adds, noting that the quality requirements for tungsten carbide powder have become increasingly stringent during the development of high-end alloy products.

For a long time, high-end tungsten carbide powder has heavily relied on imports, with imported standard tungsten carbide powder being 20% more expensive than domestic alternatives, and imported nano tungsten carbide powder even double the price. Moreover, overseas companies are often slow to respond, requiring advance orders and months of waiting. “The demand in the tool market changes rapidly; often orders come in, but raw material supply cannot keep pace,” Zhou explains.

So, what do you do when you’re dependent on others? You take matters into your own hands! In early 2021, an investment of over 80 million yuan led to the establishment of an intelligent workshop for medium-coarse tungsten carbide powder just eight kilometers from the China Tungsten High-Tech facility in Zhuzhou, Hunan, which was completed and put into production by year-end.

The intelligent workshop is spacious and well-lit. The raw material storage for coarse tungsten powder features QR codes for tracking, and automated forklifts move between reduction and carbide furnaces, handling more than ten processes—loading, unloading, and transferring—almost entirely without human intervention. In the past, the Zhuhard Company could produce only hundreds of tons of tungsten carbide powder annually, meeting just a fraction of the production needs for ordinary cutting tools. Following an all-automated digital upgrade, production costs dropped by over 30%, and capacity doubled, all while significantly enhancing product quality.

“For example, in the carbonization phase using a tungsten-carbon mixture, we’ve improved the structure and sealing of the square tube kiln to effectively stabilize temperature control during powder carbonization, while also adding automated loading and unloading capabilities to enhance work efficiency,” shares Liu Bin, Deputy General Manager of the Powder Division at Zhuhard. The challenge of producing high-quality tungsten carbide powder lies in controlling precision. Standardized intelligent equipment has replaced manual operations, boosting the consistency and stability of tungsten carbide powder, reducing the variance in key metrics between batches by half.

This technological transformation has not only enhanced efficiency and quality control but also spurred ongoing advancements in the preparation process. By precisely designing carbonization temperatures and utilizing advanced ball milling and air jet milling technologies, they ensure that the crystalline integrity and dispersion of tungsten carbide powder reach optimal conditions. “The medium-coarse tungsten carbide powder produced shows excellent uniformity, wear resistance, and thermal sensitivity—allowing us to become self-sufficient,” Liu adds. With internal control over raw materials, the production plan can be flexibly adapted to meet upstream and downstream market demands, responding swiftly to shifts in the market.

Demand from downstream industries drives technological advancements upstream, leading to continuous upgrades in tungsten carbide powder. High-quality raw materials produce superior products, with high-grade tungsten carbide enhancing the performance of downstream carbide products, allowing for applications in advanced sectors like aerospace and electronics.

Currently, the Zhuzhou Company’s market share for CNC tool inserts in China is close to 20%. In the first half of this year, sales of CNC tool inserts grew by 24% compared to the same period last year. “This year, various regions are promoting large-scale equipment updates; the replacement of outdated machine tools will further spur the development of the CNC tools industry,” says Shen Huiming, Deputy General Manager of China Tungsten High-Tech. The global demand for tools is expected to continue to rise as domestic industrial structure adjustments, manufacturing upgrades, intelligent manufacturing, and new technologies in new energy evolve.

Next to the medium-coarse tungsten carbide production line, a 250 million yuan investment is underway for an ultra-fine tungsten carbide powder intelligent production line. “We anticipate completion and production next year, with the ultra-fine tungsten carbide powder reaching international advanced levels,” Liu concludes.