Microstructural evolution and performance analysis of WC-11Co reinforced iron matrix composites

This paper presents a new fabrication method utilizing lost foam casting as a processing technique to synthesize high-strength and ultra-wear-resistant particle reinforced iron matrix composites. The composite material incorporates large-sized WC-11Co reinforcement. The composite exhibits a multiphase microstructure composed of WC-11Co, α-Fe, and carbide precipitates that extend at different length scales. The precipitation of large-sized M3W3C (M = Fe, Co) type carbides at the WC-11Co/matrix interface is well controlled. A favorable reaction layer is formed between WC-11Co and the matrix. Nano-precipitates are pinned within the reaction layer, exhibiting a high degree of coherence with the iron matrix. The stress field at the interface is complex due to thermal stress, phase transformation stress, and microstress. The stress state between WC-11Co and the matrix consists of compressive residual stress-tensile residual stress-compressive residual stress, with compressive residual stress far exceeding tensile residual stress. The WC-11Co/Fe0.35C5CrMn composite exhibits outstanding compressive strength of 2.18 GPa and a fracture strain of approximately 24.6 %. Moreover, the composite demonstrates excellent wear resistance, with a threefold improvement compared to the matrix under severe wear conditions. The following mechanisms contribute to the enhanced mechanical properties: multiphase material system, coherent multiscale interfaces, grain refinement, dislocation strengthening, and residual stress strengthening.