This article focuses on a systematic study of a Ti-6Al-4V alloy in order to extensively characterize the main mechanical properties at the macro-, micro- and submicrometric length scale under different stress fields. Hardness, elastic modulus, true stress–strain curves and strain-hardening exponent are correlated with the intrinsic properties of the α- and β-phases that constitute this alloy. A systematic characterization process followed, considering the anisotropic effect on both orthogonal crystallographic directions, as well as determining the intrinsic properties for the α-phase. An analytical relationship was established between the flow stress determined under different stress fields, testing geometries and length scales, highlighting that it is possible to estimate flow stress under compression and/or tensile loading from the composite hardness value obtained by instrumented nanoindentation testing.

Investigation of four different surface-shaping and finishing sequences is carried out on the surface integrity of a WC-10Co hardmetal grade. The surface conditions include grinding, electrical discharge machining and grinding, followed by mechanical and dry-electrochemical polishing using the DryLyte^® technology. The evaluation includes the measurement of roughness, residual stresses, the Vickers hardness, indentation fracture toughness determination and the damage induced by conical contact response. By scanning electron microscopy, a systematic and detailed examination of the residual imprints is carried out to determine the critical loads for damage initiation and development across the different surface conditions. The results indicate that the use of dry-electrochemical polishing enables the attainment of polished surfaces without any corrosive damage to the metallic binder. Moreover, it retains the mechanical attributes reminiscent of the core material, comprising 85% that were initially induced via grinding.

Precision edge preparation techniques for cemented carbides enable optimization of the geometry of tools’ cutting edges. These techniques are frequently used in high-stress environments, resulting in substantial improvements in tools’ cutting performance. This investigation examined the impact and evolution of cutting edge parameters and resulting surface finishes as a function of dry-electropolishing time on an end-mill. Findings demonstrate enlargement of the cutting edge radius, a decrease in surface roughness, and the mitigation of defects induced during previous manufacturing stages (i.e., smashed ceramic particles, burrs, chipping, etc.). Additionally, a direct correlation between dry-electropolishing time and primary cutting edges’ micro-geometry parameters has been established.

(English) WC-Co cemented carbides are widely used in industry, particularly for cutting tools, due to its exceptional combination of mechanical properties. They are composites consisting of tungsten carbide (WC) particles embedded within a cobalt (Co) metallic binder. This microstructural assemblage provides a unique combination of hardness, wear resistance, and fracture toughness. However, these properties can degrade at high temperatures (>500 ºC) due to corrosion sensitivity. To address this limitation, protective coatings, such as titanium aluminium nitride (TiAlN) or titanium silicon nitride (TiSiN) are frequently applied, enhancing performance under high-temperature loading. Grinding is the most conventional post-processing technique used to achieve the final geometry and dimensional tolerances of WC-Co components. However, this method impacts surface integrity, inducing defects like voids, cracks, high roughness (0.2 - 0.6 µm), phase transformations in the metallic Co binder, and compressive residual stresses, extending up to 10-20 µm in depth. Accordingly, removal of the damaged layer though polishing is commonly advised. In recent years, a new dry-electropolishing technology has emerged for metallic alloys, allowing precise defect reduction and surface improvement. Unlike conventional electropolishing, which uses liquid electrolytes, dry-electropolishing uses solid porous polymeric particles (ion exchange resins) filled with an electrolytic medium. This method selectively removes material layer-by-layer from surface irregularities, reducing roughness and improving surface quality. This industrial Ph.D. thesis focus on the development of a novel dry-electrolyte specifically tailored for electropolishing WC-Co composites using DryLyte® Technology. The research explores the underlying polishing mechanisms, optimizes electrical parameters, and identifies key chemical reactions involved in the process. Results demonstrate that this process effectively eliminates surface defects, reduces roughness, and preserves the WC-Co microstructure, avoiding Co leaching and WC embrittlement. A comparative microstructural and mechanical analysis was conducted, evaluating various shaping and finishing methods, including grinding, electrical discharge machining (EDM), conventional polishing, and dry-electropolishing. The findings reveal that, while grinding and EDM are widely used, they generate surface defects such as micro-cracks, porosity, and harmful oxides. Conventional polishing improves surface roughness but removes hundreds of microns of material and fails to preserve compressive residual stresses, thereby diminishing the mechanical performance of the system. Conversely, dry-electropolishing precisely eliminates deformed layers, achieves smooth surfaces between phases, and retains beneficial compressive residual stresses. The thesis further explores the industrial applications of this technology, such as cutting edge preparation for WC-Co end-mill tools. Previous studies have demonstrated that an optimal edge preparation increases tool life. The results of this research confirm that dry-electropolishing can fine-tune the cutting edge radius, refine micro-geometric parameters, reduce roughness, and eliminate manufacturing-induced defects. A direct correlation between polishing time and micro-geometric parameters is established, showing rapid changes within the first three minutes, followed by stabilization. Additionally, the research investigates the stripping of worn TiAlN/TiSiN coating on WC-Co substrates to extend their operational lifespan and reduce costs. This process removes the films precisely, leaving an oxide surface layer without compromising the substrate microstructure. The process demonstrates a linear relationship between polishing time and remaining coating thickness, ensuring a controllable, efficient, and homogeneous method. (Català) Els carburs cimentats de WC-Co s’utilitzen àmpliament en la indústria, especialment per a eines de tall, gràcies a la seva excepcional combinació de propietats mecàniques. Aquests compostos estan formats per partícules de carbur de tungstè (WC) incrustades en un aglutinant metàl•lic de cobalt (Co), aconseguint una combinació única de duresa, resistència al desgast i tenacitat a la fractura. No obstant això, aquestes propietats poden degradar-se a temperatures elevades (>500 °C) a causa de la seva sensibilitat a la corrosió. Per mitigar aquest problema, s’apliquen recobriments protectors com el nitrur de titani i alumini (TiAlN) o el nitrur de titani i silici (TiSiN), els quals en milloren el rendiment sota càrregues tèrmiques altes. El rectificat és la tècnica de postprocessat més comuna per obtenir la geometria final i les toleràncies dimensionals dels components de WC-Co. Tanmateix, afecta la integritat superficial, induint defectes com esquerdes, buits, alta rugositat (0.2 - 0.6 µm), transformació de fase del Co i tensions residuals de compressió que s’estenen fins a 10 - 20 µm de profunditat. Per aquest motiu, és habitual eliminar la capa danyada mitjançant un procés de polit. Recentment, ha sorgit l’electropolit en sec per a aliatges metàl•lics, que en redueix els defectes i en millora la qualitat superficial. A diferència de l’electropolit convencional, que utilitza electròlits líquids, aquesta tecnologia empra partícules polimèriques poroses (resines d’intercanvi iònic) amb capacitat d’absorbir un medi electrolític. Aquest mètode elimina material de les irregularitats superficials capa a capa, reduint la rugositat i millorant la qualitat de la superfície. Aquesta tesi desenvolupa un nou electròlit sec específicament per a l’electropolit de WC-Co...