This paper reviews recent advances in the synthesis of cobalt-free high-strength tungsten carbide (WC) composites as sustainable alternatives to conventional WC-Co composites. Due to the high cost of cobalt, limited supply, and environmental concerns, researchers are exploring nickel, iron, ceramic binders, and nanocomposites to obtain similar or superior mechanical properties. Various synthesis methods such as powder metallurgy, encapsulation, 3D printing, and spark plasma sintering (SPS) are discussed, with SPS standing out for its effectiveness in densifying and preventing WC grain growth. The results show that cobalt-free composites exhibit high strength, wear and corrosion resistance, and harsh environment stability, making them viable competitors for WC-Co materials. The use of nickel and iron with SPS is shown to enable the development of environmentally friendly, cost-effective materials. It is emphasized that microstructural control and phase management during sintering are critical to improve a material’s properties. The application potential of these composites covers mechanical engineering, metallurgy, oil and gas, and aerospace, emphasizing their broad industrial relevance.

This study investigates the microplasma deposition of molten tantalum (Ta) onto a rotating Grade 5 Ti Extra-Low Interstitial (ELI) alloy, producing multilayer film coatings with a porous microstructure. Optimal parameters for microplasma spraying Ta were experimentally determined to improve the surface properties of elbow joint implants. The physical and mechanical properties of the Grade 5 Ti ELI substrate and the Ta-based coating were analyzed. Moreover, mathematical modeling was utilized to determine the optimal parameters for the plasma coating process, including key factors such as spray distance, current, and rotational speed, which were systematically applied across three experimental series. A Ta coating thickness of 250 μm was achieved at 35 A current, 410 mm spray distance, and 7 rpm rotation speed under optimized deposition conditions. The results showed a microhardness increase on the Ta-coated surface, peaking above HV1000 with an average of HV742, while the Ti substrate averaged HV325. Additionally, the XRD patterns revealed the presence of metallic Ta alongside Ta oxides, such as Ta₂O and Ta₂O₅, in the Ta coatings.

This paper reviews recent advances in the synthesis of cobalt-free high-strength tungsten carbide (WC) composites as sustainable alternatives to conventional WC-Co composites. Due to the high cost of cobalt, limited supply and environmental concerns, researchers are exploring nickel, iron, ceramic binders and nanocomposites to obtain similar or superior mechanical properties. Various synthesis methods such as powder metallurgy, encapsulation, 3D printing and spark plasma sintering (SPS) are discussed, with SPS standing out for its effectiveness in densifying and preventing WC grain growth. The results show that cobaltfree composites exhibit high strength, wear and corrosion resistance, and harsh environment stability, making them viable competitors for WC-Co materials. The use of nickel and iron with SPS is shown to enable the development of environmentally friendly, cost-effective materials. It is emphasized that microstructural control and phase management during sintering are critical to improve material properties. The application potential of these composites covers mechanic

This study investigates the control of the phase-structural state in Ni–45Ti–xCu (x = 5, 7 at.%) shape memory alloys fabricated via a shortened powder metallurgy route: mechanical activation → spark plasma sintering (SPS) → heat treatment. Compact samples were produced from mechanically alloyed powders (650–750 rpm, up to 5 h) and sintered at 900 °C. The structure and microstructure were characterized using X-ray diffraction (to identify B2/B19′/Ni₄Ti₃ phases and assess ordering) and SEM–BSE/EDS (to analyze morphology, porosity, and Ni-rich precipitates). Two post-processing treatments were applied: single-stage annealing (500 °C, 2 h) and a three-stage treatment (900 °C/30 min → water quenching → 300 °C/20 min). Mechanical alloying transformed the initial elemental powder mixture (fcc-Ni, hcp-Ti, fcc-Cu) into a supersaturated fcc-(Ni, Cu, Ti) solid solution with emerging NiTi phases, with a minimum particle size achieved after ~300 min at 750 rpm. SPS compaction yielded a high-density matrix consisting predominantly of the B2 phase. Single-stage annealing preserved B19′ martensite and Ni₄Ti₃ precipitates, particularly in the 5 at.% Cu alloy. In contrast, the three-stage treatment dissolved the Ni₄Ti₃ precipitates, suppressed the formation of B19′ and R phases, and stabilized a highly ordered B2 matrix. Increasing the Cu content from 5 to 7 at.% significantly enhanced the B2 phase fraction, reduced secondary nickel-rich phases, and improved structural homogeneity, evidenced by a continuous neck network and closed porosity. The optimized condition—7 at.% Cu combined with the three-stage annealing—produced a microstructure with >95% B2 phase, <1% Ni₄Ti₃, and ~98% relative density. This forms the prerequisite microstructural state for a narrow transformation hysteresis and high functional cyclic stability.

This work investigates the effect of titanium content and the duration of mechanical alloying on the structural and phase state of powder mixtures in the Ni–Al–Ti system. The initial mixtures of Ni₆₈Al₂₅Ti₇, Ni₇₂Al₂₂Ti₆, Ni₇₀Al₂₁Ti₉, and Ni₇₅Al₂₅ were subjected to high-energy milling in a planetary ball mill for 1–6 h. It was found that the addition of titanium accelerates the dissolution of components and promotes the formation of a supersaturated fcc Ni(Al,Ti) solid solution. The most pronounced effects were observed for the Ni₇₀Al₂₁Ti₉ composition, where after 6 h of alloying, the minimum crystallite size (11.3 nm) and maximum lattice strain (1.52%) were achieved. It is shown that titanium reduces the tendency for cold welding and promotes more uniform particle refinement. The optimal conditions for synthesizing a nanocrystalline solid solution with a homogeneous structure are a titanium content of 9 at.% and a mechanical alloying duration of 6 h. The resulting powders are promising for subsequent sintering and application in structural and heat-resistant intermetallic alloys and coatings.

This paper presents a combined approach to the synthesis of WC-(Fe, Ni) hard alloys obtained by mechanical activation and spark plasma sintering (SPS). The main attention at this stage of the work is paid to studying the evolution of the morphology and phase composition of WC-(Fe, Ni) powder mixtures during high-energy milling and their subsequent sintering by the SPS method. The study analyzed the effect of the mechanosynthesis time and the binder phase content on the change in the average particle size, the degree of defect formation, and the phase composition of the powders. It was found that an increase in the milling time to 240 min promotes the formation of the WC nanocrystalline structure and the accumulation of microdefects, which is accompanied by a decrease in the average particle size and an increase in the dislocation density. The X-ray phase analysis of the samples after SPS confirmed the preservation of the WC phase and the formation of the γ-(Fe, Ni) matrix without the formation of secondary carbide phases. The analysis of sample shrinkage showed three main stages: initial compaction, intense shrinkage, and structure stabilization. The obtained data demonstrate that optimization of the parameters of mechanical activation and SPS allow for effective control of the phase composition and morphology of WC-(Fe, Ni) powders, which opens up opportunities for their subsequent study in conditions of aggressive environments and radiation exposure.