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The research results conducted on binderless tungsten carbide (WC) ceramics obtained by Spark Plasma Sintering (SPS) of WC powders with different average particle sizes (0.095, 0.8, 3 μm) are presented. Nonuniform distribution of crystalline phases and microstructure of the WC ceramics was studied using layer-by-layer XRD analysis and SEM. Surface layers of the WC-based ceramics are characterized by nonuniform distribution of W2C crystalline phase and grain sizes, including the appearance of abnormally large grains. Thickness of the nonuniform layer was at least 50 μm. The effect under study is associated with an intense carbon diffusion from graphite foil. On the one hand, this contributed to a decrease in the intensity of W2C phase particle formation, which is transformed into α-WC phase due to the carbon. On the other hand, it caused abnormal grain growth in the layer where the carbon diffused. The obtained value of the carbon diffusion depth exceeds the values known from the literature (up to 1 μm in the case of volume diffusion even at temperature of 2370℃ and exposure time of ~ 60 h). The use of boron nitride (BN) as a protective coating on graphite mold parts did not prevent the formation of nonuniform layer on the ceramic surface.

This paper investigates the density, phase composition, microstructure and mechanical properties (microhardness, fracture toughness) of binderless WC + SiC ceramics obtained by conventional pressureless sintering (CPS) and Spark Plasma Sintering (SPS). α-WC nanopowders obtained by DC arc plasma chemical synthesis and β-SiC powders have been used as raw materials. The content of SiC particles was 1, 3, 5% wt. Excess graphite (0.3, 0.5% wt.) was added to α-WC nanopowders to decrease the volume fraction of W2C particles that negatively affect the mechanical properties of ceramics. WC + 1% wt. SiC + 0.3% wt. C ceramics are shown to have a homogeneous fine-grained microstructure, high relative density, increased microhardness and Palmquist fracture toughness. The CPS and SPS activation energies of WC + SiC nanopowders at an intensive shrinkage stage are determined using the Young-Cutler model. The effect of carbon and SiC particles on the CPS and SPS activation energies of tungsten carbide nanopowders has been analyzed. The CPS activation energies of WC, WC + C and WC + SiC + C nanopowders are shown to be closer to the carbon diffusion activation energy along α-WC grain boundaries. The SPS activation energies of WC and WC + SiC nanopowders turn out to be lower than the carbon grain boundary diffusion activation energy of α-WC.