Tungsten Carbide drill bits are used in many applications including drill bits for the manufacturing industry. Carbide drill bits come in various sizes and have a multitude of uses within the industry.

Carbide drill bits are usually attached to some sort of tool, usually a drill which forces the drill bit to rotate and provides adequate torque to create a hole for the intended purpose.

Carbide drill bitsTungsten Carbide and carbide mixes are extremely hard and can produce appropriate drilling capabilities in most all materials while holding a sharp edge longer than other bit materials. Because of its durability, Tungsten Carbide can be rather expensive so that is why industries are using more recycled carbide tools. Carbide recyclers are collecting scrap carbide from various industries and machine shops to process through carbide recycling methods.

The use of Tungsten Carbide in drill bits provides a longer lasting, stable, and solid material for use in drilling within numerous industries. Carbide recyclers process the scrap carbide through their facilities and send this cleaned material out to manufacturers who reform the carbide into new products such a carbide drill bits.

Carbide drill bits can be either solid tungsten carbide or merely have the tips covered in a Tungsten Carbide cement.These Carbide drill bits are preferred in construction, mining, farming, automotive and machine shop industries due to their long life. As with any metal of drill bit, there is always wear and tear, dulling, and sometimes breakage. Machine shops can resharpen carbide drill bits in order to further lengthen their usage life. The carbide scraps, filings and sludge can then be delivered to carbide recyclers for the best current scrap carbide pricing. Carbide-USA provides specific instructions on how to keep the carbide scrap separate from other metals and how to properly deliver to their offices.

The major benefit of carbide drill bits is that they provide a longer working life due to their hardness factor. Hardened steel is not able to last as long in steady applications as Tungsten Carbide. By utilizing carbide material, industries can keep their tools on line in the field for longer periods of time preventing down time and loss of time spent on a project.

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This article will go on to describe the affecting reasons that the length of tungsten electrode service life on quality and productivity of pipe welds in “Tungsten Electrode Service Life and Its Value in Stainless Steel Pipe ProductionⅠ”:

(3) Under the sustained action of arc cathode up to thousands of degrees high temperature, the ends of the tungsten electrodes will eventually appear oxidized ablation. When the operator find that the shape of the ends of the tungsten electrode has changed and is not sufficient to ensure penetration quality, it is the time to shut down to replace or re-sharpen the electrode tip during continuous welded pipe production. This downtime often cause some scrap stainless steel tube, thus affecting the rate and productivity of the welded pipe.

(4) In the single pipe production, the length of each pipe is typically 4-6 mm. In order to improve productivity and reduce rework pipe volume, it should be avoided that a half-way stop to replace the tungsten electrodes.

(5) In order to obtain as high welding speed and productivity pipe as possible, the parameter (big tungsten rod diameter and the highest allows use of welding current) is always chosen in accordance with the thickness of welded pipe. The results of a research institute showed that: the burning loss of cerium tungsten electrode (a diameter of 2.4 mm) is slightly larger than lanthanum tungsten electrode and yttrium tungsten electrode only when it’s current is more than 230A. However, if it is less than this current value, the cerium tungsten electrode is better than the above two. The former arc reliability is better than the latter one. This is because: tungsten, lanthanum, thorium electron work function, is respectively 4.5 eV, 3.3eV and 3.35eV, while cerium electron work function is only 2.6eV.



 

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Tungsten electrode service life refer to welding time that after a cutting grinding and under arc conditions, tungsten electrode end shape is stable and allows continuous or accumulated stainless steel pipe welding. Whether during single or continuous welded pipe production, the length of the time will directly affect the quality and productivity of pipe welds, this is because:

(1) In the GTAW(namely Gas Tungsten Arc Weld) production and applications, if the end shape of the tungsten electrode is changed, then its arc shape will change as well, that is to say, current density distribution, the current field shape, the size of Plasma air drag force and electromagnetic force (Lorentz magnetic) field distribution in the arc will change.

(2) In the PAW (Plasma Arc Welding) production and application, if the shape of the tungsten electrode tip is changed, the central position of electrodes material tip and its effective neck-in will produce offset within the plasma welding torch, resulting in a plasma arc is compressed and its flow power fluctuations, thus affecting the keyhole effect, that is to say, it will have an influence on the stability of the weld penetration quality.、


 

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There are several conclusions discussed below on failure research of the tungsten electrodes under high pressure environment:

(1) Failure form of tungsten electrodes are three forms, showed in the following: tungsten electrodes melting, tungsten electrodes erosion and tungsten electrodes tip stick on metals. Among them, tungsten electrode melting account for about 1%; tungsten electrode erosion possesses the largest proportion, which is 90%, the tip will blunt after the tungsten electrode erosion; while the proportion of tungsten electrode tip stick metal is 9 percent, tungsten electrode which sticking to the metal can no longer arc.

(2) Gives the geometric criterion of tungsten electrode failure.

(3) Under high-pressure conditions, there are a lot of factors affecting tungsten electrodes failure, such as, protective gas effects and workpiece surface status. You can use the following methods to study measures to prevent the failure of tungsten electrodes: establish tungsten electrode failure fault tree under high pressure conditions, conduct quantitative and qualitative analysis of fault tree to identify the minimum cut set, and then calculate the structure importance coefficient of the events. Eventually, develop relevant measures to prevent the tungsten electrode failure on the basis of the aforementioned analysis.



 

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Carbide testing can be quick and easy if you follow the steps below

1.The first step to carbide testing is to see if your carbide is heavy? It does not take a lot of carbide for the weight to add up. Carbide is much heavier then steel is.  A coffee can full of carbide will weigh around 50 pounds while the same coffee can full of steel would weigh around 25 pounds.

2.Carbide testing with a magnet is very easy. First question is it magnetic? True tungsten carbide has very little attraction to a magnet. You should be able to easily pull the magnet away from the carbide. If your magnet is hard to pull away from the tool it is steel.

3.spark-test:How much does the material spark? If you place a piece of carbide on a grinding wheel the spark will be close together and the spark will be more orange in color. While a piece of steel will spark like a sparkler and the sparks will be whiter.

These three great ways of carbide testing while allow you to be confident in what you have is carbide.

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Pure tungsten and doped tungsten are common anode material, and thorium tungsten, lanthanum tungsten are acting as cathode material. In order to improve the high temperature strength and the recrystallization temperature of tungsten, lanthanum oxide may be employed as the dispersed reinforcing phase. Therefore, lanthanum tungsten electrodes (W - La₂O₃ alloy) are often used as an electrode material. German KIT researchers had adopted tungsten powder with Fisher particle size (1-3 micron) to conduct MIM experiments of lanthanum tungsten electrodes, after sintering at 1600 ℃, then conducting the hot isostatic pressing to obtain basic fully dense parts. The density of lanthanum tungsten electrodes can be improved by increasing the sintering temperature and hot isostatic pressing treatment, but it is often limited by equipment and cost. On one hand, study more granular tungsten powder to do MIM experiment, on the other hand, use Ni as an activating element, studying its effect on the sintering density, and finally successful use of MIM technology to develop a kind of W - 1.5% La₂O₃ electrode with cuppy shape.

Remarks:

1. Fisher particle size: The average particle size of the powder measured by Fisher method. Fisher method is a relative measurement method; we can not accurately determine the true size of powder, it is only used to control the quality processes and products.

2. MIM, namely, Metal Injection Molding, which is a kind of forming method that injecting the plasticized mixture of metal powder and its binder in the model. 

 

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In recent years, people have pay more and more attention to metal injection molding of refractory metal, which is mainly used to produce parts of complex shape of small size, we call it MIM for short, and its full name is Metal Injection Molding. Under normal circumstances, this type of parts is functional unit under high temperature, and the requirement of high temperature strength and fatigue performance are relatively not so harsh, although this reduces the density requirements, but it achieves a nearly net shape, reducing the machine processing costs. Tungsten, owns the highest melting point at the refractory metals, which is the most widely used lighting electrode material.

The traditional preparation process of tungsten electrodes is showed as bellow: machining the tungsten rod which has been sintered and deformed to give pure tungsten / tungsten alloy electrodes. Because tungsten belongs to rare metal and its machining is difficult, therefore, net forming of tungsten electrodes are more and more paid attention in recent industry. Philips Advanced Metrology Systems Corporation is one of the earlier units to carry out a refractory metal injection molding research and development, the use of MIM to manufacture high-pressure gas discharge lamp with tungsten electrodes, in comparison with conventional tungsten electrode wounded with tungsten wire, MIM can achieve tungsten electrodes with different and complex shapes, which facilitate designers to design its shape according to the function of the electrode.



 

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Tungsten has increasingly been applied in aerospace, chemical and nuclear and other fields, it is suitable for welding almost all of metal, especially active metals of refractory metals, nonferrous metals and alloys, titanium and its alloys, stainless steel and high temperature alloys.

Pure tungsten electrodes under high temperature will recrystallize to form equiaxial and coarse grain structure, what will result in the decrease of its mechanical properties. What is more, because the current capacity of pure tungsten is small, the work function (4.52eV) is high, so that the burning would be more serious under large currents. Therefore, the scientists discovered thorium tungsten electrodes material in 1913. Thorium tungsten electrode is the first used electrode in rare earth tungsten electrodes, its good performance and higher market share, what makes it one of the main hot electron emission materials currently, however, thorium element have a radioactive, its half-life grew 1.39 * 10¹⁰, In the production and use processes and its waste will have a great harm to the environment.

In view of this, in the 1970s, the former Soviet Union has started to develop a new type of electrode material, while China factories are almost successful trial-manufacture the cerium tungsten electrodes and make it popularization and application at this time. Thanks to cerium tungsten electrodes themselves own advantages, such as, no radiation pollution, good low-arc arcing performance, so it has become the preferred alternative between the small-diameter welding and low-current welding. However, there are still some limitations in the use of cerium tungsten electrodes, and therefore it can not fully replace the thorium tungsten electrodes.

 

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This article describes that the RE (rare earth) tungsten electrode, as green tungsten electrode, has been gradually developed to replace the traditional radioactive thorium tungsten electrode material.

Chinese tungsten and rare earth resources reserve and production occupied an absolute advantage. Tungsten is known as the "war metal", "Industrial salt", and the rare earth is called "industrial MSG", as you can know from the name, tungsten and rare earth is playing an irreplaceable role in today's high-tech areas. Because they all have higher temperature performance, so they have a wide application in metallurgy, energy, defense industry, electronic information, the nuclear industry and aerospace and many other fields, and they have become indispensable material in the national defense and civilian facilities which is related to human lives.

Under normal circumstances, rare earth tungsten electrode material can be successfully prepared when tungsten acts as a host material and doped with rare earth oxide (with relatively low electron work function). Because the rare earth metal oxides own excellent thermal electron emission capability, rare earth tungsten electrode material may be, on the one hand, to improve the recrystallization temperature of the material, on the other hand, it can start the electron emission. Therefore, rare earth tungsten electrode material has been to a development direction on replacing the traditional radioactive thorium tungsten electrode material.



 

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Because it is the coordination that required by the welder, manual gas tungsten arc welding is a relatively difficult welding method. What is similar to torch welding is that GTAW normally requires two hands. Since that most applications require the welder manually feed a filler metal into the weld area with one hand while manipulate the welding torch with the other. Maintaining a short arc length is also important while preventing contact between the electrode and the workpiece.

To strike the welding arc, a high frequency generator, which is similar to a Tesla coil, provides an electric spark. This spark is a conductive path for the welding current through the shielding gas and allows the arc to be initiated while the electrode and the workpiece are separated, typically about 1.5–3 mm (0.06–0.12 in) apart.

Once the arc is struck, the welder moves the torch in a small circle to create a welding pool, the size of which depends on the size of the electrode and the amount of current. While maintaining a constant separation between the electrode and the workpiece, the operator then moves the torch back slightly and tilts it backward about 10–15 degrees from vertical. Filler metal is added manually to the front end of the weld pool as it is needed.

Welders often develop a technique of rapidly alternating between moving the torch forward (to advance the weld pool) and adding filler metal. The filler rod is withdrawn from the weld pool each time the electrode advances, but it is always kept inside the gas shield to prevent oxidation of its surface and contamination of the weld. Filler rods composed of metals with a low melting temperature, such as aluminum, require that the operator maintain some distance from the arc while staying inside the gas shield. If held too close to the arc, the filler rod can melt before it makes contact with the weld puddle. As the weld nears completion, the arc current is often gradually reduced to allow the weld crater to solidify and prevent the formation of crater cracks at the end of the weld. 

 

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